Stationery Storage and Retrieval System
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
CHAPTER 1
PROJECT INTRODUCTION
1.1INTRODUCTION
Nowadays, Industrial Technology is well known very synonym with automation.
This is because of automation’s reliability and more importantly it does save cost
especially manpower. Thus, our group decides to produce a project that implements
automation in operation process.
In this final year project, specialize in Mechatronics; we are required to produce an
automated machine process base on the chosen product. For our group, we have chosen
stationery merchandise as our product to develop our project, a Stationery Storage and
Retrieval System (SSRS).
These machines have six process sequences which are; initializing I/O card, user
verification, menu selection, item selection, confirm item and collects item. The machine
comes with systems that make it intelligent enough to perform its task with minimum
supervision. Besides, to make it compatible with other machine, the system is complete
with user friendly unlimited items requested (e.g. user can request for any items several
times) and some additional safety features for both; product and the user.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
The SSRS is eventually an ideal method for the lecturer and trainees to acquire or
review basic theoretical and practical knowledge in Mechatronics field. It is a combination
of electrical, electronics, mechanical, PLC and computer programming. Every module is
designed to perform a specific function such as smart storage, loading, inspection and etc.
Standard components such as motors and sensor are integrated into each module to
achieve the desired function.
It is an innovative creation project base on the concept of the vending machine
available in the market nowadays. Thus, this machine is specially designed according to
the needs of office personnel for organizing the usage of stationery merchandise. It will
also help to build up a better management and increased the productivity.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
1.2 OBJECTIVE
1.2.1 MAIN OBJECTIVES
The main objectives of this Final Year Project is to let us gain experience in
designing, electrical wiring, programming and troubleshooting a machine. We also apply
the knowledge learned in GMI especially in the Mechatronics field. The given opportunity is
to change idea with group member and deal with other members to exchange information.
We were also having learned the communication skill when dealing with the
vendors. This is also to expose us to the real working life experience as a project team in
the engineering field.
During the project implementation process, we also have learned to increase
knowledge about machine design and automation element. To manage the project and
have the cooperation among the group members is an important part where without it the
project can’t be done properly. Finally, cooperative with supervisor is also the important
thing where we have to respect him as our guidance since doing this project.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
1.2.2 PROJECT OBJECTIVES
SSRS applies all the knowledge that Mechatronics student gained all through the
previous semester. Furthermore, this project also has advantages that enhance its
specialty. As a result, this machine could help to improve the lifestyle of humanity to
become more organized.
The main objectives of this project are stated as below:
• Designed a machine that can organize the stationery merchandise.
• Developed a system that fully controlled by computer base.
• Developed an efficient office management by equip the latest technology for
monitoring system.
• Improved inventory system and simulate the industrial practices on realistic
industrial system model.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
1.3 PROJECT SPECIFICATION
NAME Stationery Storage and Retrieval System (SSRS)
PRODUCT Stationery merchandise and Office Equipments
FUNCTIONDispense stationery merchandise and improve inventory
system.
VOLTAGE SUPPLY 220 ~ 240V AC, 2.5 A, 50 Hz
POWER SUPPLY UNIT 5V DC, 12V DC, 24V DC
MACHINE DIMENSION 1000mm x 1000mm x 1950mm (include tower lamp)
SENSING1) Limit switch
2) Inductive sensor
DRIVE SYSTEM
1) DC Motor (12V DC)
2) Stepper motor
3) Gear
4) Chain
TRANSFERRING SYSTEM1) Movable Pusher
2) DC Motor (12V DC)
OUTPUT SYSTEM1) Silo
2) Discharge Section
CONTROLLER
1) Programmable Logic Control (PLC) SIEMENS
Step 7-200
2) Position Module EMS 253
3) Motor Driver
4) PC I/O card
DATABASE SYSTEM Visual Basic 6
OPERATING SYSTEM Manual
INDICATOR
1) GREEN for operating region
2) YELLOW for transferring
3) RED for stop
Table: Project Specification of SSRS.
1.4 FEASIBILITY STUDIES
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
Before we propose this project to the project committee, we have started our
feasibility studies on the main problems involved stationery issue in an office management.
The problems were inventory system for stationery and uncontrolled usage of stationery.
We choose Industrial Electronics (IE) department as a reference to gain more information
about that issue.
Diagram 1 : IE Department.
After identified the source of problems and gain information at IE department, we
made a short listed items. The short listed items are the highest demand by user. So, we
choose the most relevant and convenient items to used as the products to our project.
From the list of items, we went to the stationery shop to get the dimension of the
products for a design purpose.
Diagram 2 : Stationery Shop.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
Diagram 3 : Example of stationery items.
We also do some research in Visual Basic programming because this project
involved Visual Basic 6 as the interface for the machine and the database for the
inventory.
Diagram 4 : Learning process for VB programming.
For drive mechanism, we decide to use two stepper motor, four DC motor, pulleys
and belting. But, after propose the project; we were advised to used just one stepper motor
and two DC motor and also during project implementation, there were some problems
occur and we have to change the design from using pulley and belting to using chain and
gear.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
Diagram 5 : Equipments of drive mechanism.
1.5 PROJECT FEATURES
In order to make this project successful, there are several factors should be
considered. This project fulfils these factors by means of profit return in investments. It is
efficient enough to increase the production rate in ways of shorter and constant. The
safety features provided is also secured both user and product harm.
PC I/O CARD
Diagram 6 : PC I/O card and Terminal block for PC I/O card.
The I/O card we are using in this project is EX 94632. This I/O Card is used to send
signal from Visual Basic 6 button to PLC Siemens S7-200. The I/O Card has it own
terminal block to distribute the input and output from either PC or PLC. We install this card
at the PCI Slot. The output trigger from I/O card is 5 Volts, so we need something to switch
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
from 5 Volts with 24 Volts. This I/O card has it own code to be programmed in the Visual
Basic 6; we need to configure which code is suitable for Initializing and set ON and OFF.
OPTO-COUPLER
Diagram 7 : Figure of Opto-coupler circuit.
Besides that, this project involves very highly skill in Mechatronics. In example, the
electronic circuit is design and done by ourselves. The electronic circuit contains Opto-
Coupler for switching the voltage from 5 volts with 24 volts. The opto-coupler used to
trigger Programmable Logic Control (PLC) Siemens S7 – 200 from I/O card. The output
from I/O card is 5 volts, so, to trigger the PLC it need 24 volts. Besides, the opto-coupler is
far faster switching compared to relays. That the reason why we used Opto-Coupler.
VISUAL BASIC 6
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
Diagram 8 : Visual Basic 6.
Visual Basic 6 is used as the interface for the machine and the database for the
inventory. We decided to do this project with visual basic because of the increasing of the
computer based control lately. We do the research and study the basic programming code
to implement the proposed project. We managed to finish the interface within 3 months of
study. After that we developed it to make it more interesting and finally we learn on how to
communicate from the Visual Basic 6 with Siemens s7-200. Our system consists the
inventory of item has been dispense by user and selection menu for user to choose
stationary items.
SYSTEM COMMUNICATION
Diagram 9 : PPI Cable and Ribbon Cable.
The communication system using in this project is, for PC to PLC programming weused PPI Cable that is RS 232 to RS 485. For I/O card to Terminal Block we used flat
Ribbon Cable as a connector.
DRIVE MECHANISM SECTION
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
Diagram 10 : Drive Mechanism Section for SSRS.
For the drive mechanism section, the design at first involved 2 stepper motor to
moved it. But, it cause more cost. After discussion, we decided to use only one stepper
motor. So we start to fabricate the drive mechanism which is involving lot of mechanical
movement. The drive mechanism section contains, two power window motor for forward
and reverse of the pusher rod, positioning table to move the pusher rod, chain to move the
positioning table taken from the movement of stepper motor. The design at first used
timing belt, but due to GMI payment policy we cannot use the timing belt. We find the
solution on how to replace it by using chain
STEPPER SECTION
Diagram 11 : Stepper Section of Drive Mechanism Section.
This section is fully designed and fabricated by our group. This section contains
table mounting, stepper motor and drives mechanism. This section is static due to only
gear is moved by stepper to rotate the chain to move the positioning table.
POSITIONING TABLE
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STEPPER SECTION
POSITIONING
TABLE
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Diagram 12 : Upper and Bottom of Positioning Table.
This positioning table consists of DC Motor, Pusher Rod, Positioning Table, Limit
Switch, Gear and Chain. This section is one of the most important part because the used
of pusher to dispense items. Positioning table is fully designed and fabricated by our own.
We put lot of effort to finish and to align the position of this table.
BEARING FLANGE
Diagram 13 : Bearing Flange of Drive Mechanism Section.
Bearing flange we used is to replace the real bearing flange by fabricate it on our
own. It is to reduce our cost and it is proven save cost. The bearing actually, we attach to
the metal plate by weld them together. Maybe the design is not similar with the real one,
but it has similar function with the real bearing flange.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
MOVABLE MAGAZINE DRAWER
Diagram 14 : Upper and Bottom movable drawer magazine.
This kind of drawer is fabricated by us with user friendly design. So, it makes the
drawer easy to put in or put out. The drawer contains guide rail attach with bearing in the
middle to smoothing the movement of the rail. At the back of the rail, it has stopper to
prevent the drawer from over limit of the rail. Beside that, the rail also has lock to prevent it
from slide.
THE SIX PROTOCOLS
This machine consists of six sequence of protocol to be complete to get the end
product. This protocol shows the features of this project on the machine:
1) INITIALIZING I/O CARD
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UPPER DRAWER BOTTOM DRAWER
GUIDE RAIL
LOCK
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
Diagram 15 : Initializing I/O Card
Initializing for I/O card is important because it is to activate the card for the next
operation. Only by activating this card, user can proceed to the verification protocol.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
2) USER VERIFICATION
Diagram 16 : User Verification
Username and password for account verification. It is to retrieve user profile to
activate the system. When the system activated, selection menu will pop-up.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
3) SELECTION MENU
Diagram 17 : Selection Menu
Selection Menu is use to select next protocol. It is contains of Items Menu and
Purchase History. Items Menu is used to select item and Purchase History is used to view
user history profile. Once selection had been made, it will go to the next menu.
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4) ITEMS SELECTION
Diagram 18 : Items Selection
This protocol consist list of items. User can select any items enormously.
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5) CONFIRM ITEMS
Diagram 19 : Confirmation Of Items
Once user had chosen the needed item, system will prompt the user with
confirmation task bar for each item. Finish with the confirmation, then the drive mechanism
will move the positioning table to extend the pusher at selected item magazine. The item
will dispense at silo and discharge section.
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FINAL YEAR PROJECT DOCUMENTATIONSTATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)
6) COLLECT ITEMS (pic)
Diagram 20 : Collect item
This is the end of the protocol. User may collect their items after completing all theprotocol. Collect items can be made at the discharge section.
CHAPTER 2
PROJECT IMPLEMENTATION
2.1 SYSTEM LAYOUT
The system layout is comprised of four types of machine layout diagram:
1. Assembly drawing
2. Front view
3. Side view
4. Top view
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2.1.1 MACHINE LAYOUT DIAGRAM
ASSEMBLY DRAWING
Diagram 21 : Figure of 3D and actual assembly drawing for SSRS.
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FRONT VIEW
Diagram 22 : Figure of 3D and actual front view for SSRS.
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SIDE VIEW
Diagram 23 : Figure of 3D and actual side view for SSRS.
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TOP VIEW
Diagram 24 : Figure of 3D and actual top view for SSRS.
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2.1.2 ELECTRICAL WIRING DIAGRAM
Diagram 25 : Figure of electrical wiring diagram for SSRS.
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2.1.3 ELECTRONICS WIRING DIAGRAM
CIRCUIT OPTO CUPLER – (16 bit)
OPTO COUPLER (A5) OPTO COUPLER (B5) OPTO COUPLER (C5)
OPTO COUPLER (D5) OPTO COUPLER (E5) OPTO COUPLER (F5)
OPTO COUPLER (G5) OPTO COUPLER (H5) OPTO COUPLER (I5)
OPTO COUPLER (J5) OPTO COUPLER (K5) OPTO COUPLER (L5)
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OPTO COUPLER (M5) OPTO COUPLER (N5) OPTO COUPLER (O5)
OPTO COUPLER (P5)
Diagram 26 : Figures of opto-coupler wiring for SSRS.
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2.1.4 PLC WIRING DIAGRAM
Diagram 27 : Figure of PLC wiring for SSRS.
LAGEND
A5 OPTOCOUPLER
B5 OPTOCOUPLER
C5 OPTOCOUPLER
D5 OPTOCOUPLER
E5 OPTOCOUPLER
F5 OPTOCOUPLERG5 OPTOCOUPLER
H5 OPTOCOUPLERI5 OPTOCOUPLER
J5 OPTOCOUPLER
K5 OPTOCOUPLER
L5 OPTOCOUPLER
M5 OPTOCOUPLER
N5 OPTOCOUPLER
O5 OPTOCOUPLER
P5 OPTOCOUPLERK1 RELAY (FORWARD DC MOTOR)
K2 RELAY (REVERSE DC MOTOR)K3 RELAY (FORWARD DC MOTOR)
K4 RELAY (REVERSE DC MOTOR)
H1 TOWER LAMP(GREEN)
H2 TOWER LAMP(YELLOW)
H3 TOWER LAMP(GREEN)
Table: Lagend for SSRS PLC wiring diagram.
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Diagram 28 : Figure of PLC wiring for SSRS.
LAGEND
PB1 INITIAL CONDITION
PB2 STOP MOTORLS1 FORWARD DC MOTOR
LS2 REVERSE DC MOTORLS3 FORWARD DC MOTOR
LS4 REVERSE DC MOTOR
Table: Lagend for SSRS PLC wiring diagram.
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2.1.5 POSITION MODULE WIRING DIAGRAM
Diagram 29 : Figure of position module wiring for SSRS.
LAGEND
CCW+ STEPPER DRIVER MOTOR
CW+ STEPPER DRIVER MOTORCCW- STEPPER DRIVER MOTOR
CW- STEPPER DRIVER MOTOR
S1 INDUCTIVE SENSOR
L 0V
M 0V
Table: Lagend for SSRS position module wiring diagram.
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2.2 INSTRUMENT AND EQUIPMENT SPECIFICATION
The instrument and equipment for this machine divided into:
1. Mechanical
2. Electrical and Electronic
2.2.1 MECHANICAL COMPONENT
Table: Mechanical component specification.
2.2.2 ELECTRICAL AND ELECTRONIC COMPONENT
Component Description
Block with flange
Material : Aluminum
Size : 200X280mmFunction : Positioning Table
Bearing FlangeSize : 40x40mm
D= 27.4mm, d= 10.6mmFunction : Bearing Flange
Drawer MagazineMaterial : Mild Steel
Function : To placed items in magazine
Pusher
Material : Aluminum
Size : D= 12.7mmFunction : To dispense items from magazine
Gear (14 tooth)Material : Mild SteelSize : 14 toothFunction : Drive chain for positioning table
Gear (27 tooth)
Material : Mild SteelSize : 27 tooth
Function : Drive chain for positioning table
Chain
Material : Mild SteelSize : 324 (Industrial Standard)
Function : To move the positioning table
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Component Description
Emergency StopPush Button
Input : 240 VACOutput : 240 VAC
Selector SwitchInput : 240 VACOutput : 240 VAC
PLCModel : Siemens S7 200Input : 24 VDCOutput : 24 VDC
Position ModuleModel : Siemens EM 253Input : 240 VACOutput : 5 VDC
Power WindowMotor
Output : 12 VDC
ELCBInput Voltage : 240VACOutput Voltage : 240VAC
MCB
Model : ABB, Hager
Input Voltage : 240/415VInput Voltage : 6AModel : Hager Input Voltage : 240/415VInput Voltage : 16AModel : TAIAN JAYAInput Voltage : 230/400V 50 HZ & 230/415V 50HZInput Voltage : 6C & 6A
Opto-coupler Type : 4N25
Resistor Type :100 ohm
1000 ohm
Stepper Motor
Model : MYCOM
Input : 24VDC
Inductive sensor Input :24VDC
Limit switchInput : 12VDC
Motor Driver Model : MYCOMInput : 24VDCOutput : 24VDC
Power Socket Type : 3 Pin
Table: Electrical and electronics component specification.
2.3 PROCESS PLAN
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2.3.1 BLOCK DIAGRAM
Diagram 30 : Figure of block diagram for SSRS process plan.
2.3.2 MACHINE PROCESS FLOWCHART
PROTOCOL 2:
USER VERIFICATIONPROTOCOL 1:
INITIALIZING I/O CARD
PROTOCOL 3:
USER MENU
PROTOCOL 6:
COLLECT ITEM
PROTOCOL 5:
CONFIRM ITEM
PROTOCOL 4:
ITEM SELECTION
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Start
User need to initialize
I/O Card
Initializing
ok?
Insert username and
password to login
Login
ok?
User selection
menu
Selectok?
Item selectView item
history
1.0 2.0
Yes
No
1
No
Yes
End
Report of dispense
items
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1
WritingPad
Refill
Red
Stapler
Refill
Blue
MemoPad
Refill
Black Thumb
Tacks
Ok?
Ok? Ok?
Ok?
Ok?
Ok? Ok?
Fastener
Ok?
End
Proceed
Proceed
Proceed
Proceed
Proceed
Proceed
Proceed
Proceed
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No No No
No No No
3
3 3 33
3 3 3
2
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2
Marker
Blue
Black
Pen
Marker
Red
Stapler
bullet
Paper
ClipA4 Paper
Ok?
Ok? Ok?
Ok?
Ok?
Ok?
Blue Pen
Ok?
Marker
Blue
Ok?
Proceed
Proceed
Proceed
Proceed
Proceed
Proceed
Proceed
Proceed
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
No
3
3
3
3
3
3
3
3
End
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Diagram 31 : Figure of machine process flowchart for SSRS process plan.
2
Positioning table move
to the desire item
Pusher Extend
Pusher Retract
Positioning table
back to initial
End
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2.3.3 MACHINE SEQUENCES
In order to use the SSRS, users have to follow the sequence to dispense item.
Stated below is the sequence on how to operate the vending machine.
Protocol 1:
• User need to initialize I/O card as 1
• Then click enter for the next protocol
Protocol 2:
• User need to identify themselves to activate the system using user ID and
password
• Wait for the identification success for the next step to activate
Protocol 3:
• After identification successful, user needs to choose Select Items to select items or
Purchase History to view profile. (Select Profile is nothing to do with the sequence
to dispense items. It’s to view user profile only such as balance and total of items
that has been dispensing from user)
• Choose Select Items to continue the process
Protocol 4:
• New menu for items will pop-up
• Select the item that user wanted
Protocol 5:
•
Clicks the item to confirm and proceed for the dispense item
Protocol 6:
• Collect item at the discharge section
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2.4 START-UP, COMMISSIONING AND TEST
2.4.1 QUALITY CHECKING
First thing to do before use the recycled parts from previous or receives the items
from vendors, we need to have a quality checking to ensure the items are in good
condition and function well. The following table is the checking procedure for electrical
equipment.
Table: Quality checking for electrical component.
2.4.2 START-UP
ITEMS CHECKING PROCEDURES
MCB and ELCB • Check continuity using Multimeter.
• Check current rating to make sure it is able to
protect the system from overload current.
• Check resistance reading when switch is on,
ensure it is zero.
5V DC, 12V DC,
24V DC Power
Supply
• Apply 240V AC to Power Supply input,
• Read the output; make sure it is 5V DC, 12V DC
and 24V DC
Emergency Stop
Button
• Ensure it has a NC contact.
• Check continuity using Multimeter.
PLC • Download a simple program to PLC
• Give 24V DC to all PLC inputs.
• Check the output voltage using Multimeter to
determine whether it sense the signal or not.
Inductive Sensor • Apply 24V DC to the sensor
• Check the output voltage using Multimeter.
Stepper Motor • Apply 24V DC to motor.
•
Test runs the motor.Motor driver • Apply 24V AC to motor driver
• Test runs the motor driver
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For a convincing and proper start-up, please follow the instructions given
below to operate the machine.
1. Plug-in the power cord to a 415V AC/ 230V AC/ 240V AC supply
and turn the Selector Switch.
2. Switch ON the ELCB and all the MCBs.
3. Release the EMERGENCY STOP Buttons.
4. Turn ON the PC and monitor.
5. Key in user ID and password on the monitor to be allowed to use the
machine.
6. Double click on Stationery Storage And Retrieval System Icon at the
Start Menu.
7. Follow the instruction given in the system.
NOTE: This machine only run the MANUAL mode.
2.4.3 COMMISSIONING AND TEST
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2.4.3.1 CHECK LIST FOR ELECTRICAL COMPONENTS
Table: Checklist for electrical component functionality.
2.4.3.2 PROBLEM ENCOUNTERED AND COUNTERMEASURES
PROBLEM ENCOUNTERED COUNTERED MEASURES
• Items unable to dispense from magazine • Change the design and quantity
packaging of items
• The cancellation of belting and timing
pulley due to college policy
• Change the design from using pulley
and timing belt to chain and gear.
• Touch screen configuration class has been
cancelled. We cannot configure our touch
screen to communicate with PC and PLC
• We used PC monitor to replace touch
screen
• The stepper positioning is not fix to the
place for pusher to stop due to the used of
chain. The pusher have idle before the
operation
• In the Ladder Diagram, we set the
timer for done signal for each step
longer. So, the position of the pusher
can be seen before it pushes the item.
ITEMS FUNCTIONALITY
MCB and ELCB Good
5 VDC, 12 VDC, 24 VDC Power Supply GoodEmergency Stop Button Good
PLC Good
Inductive Sensor Good
Stepper Motor Good
Motor driver Good
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We can abort the operation if the
pusher is not in place.
Table: Problem encountered and countermeasure.
2.5 RESULT AND DISCUSSION
After finish the project implementation process, we must run the commissioning
and testing procedure to get the result of the project performance.
Due to the testing, it shows result that this machine able to run upon expectation.
The entire components function well and give an excellent result.
There were some problems occurs during the implementation process but we
manage to overcome the problems efficiently.
The result of commissioning:
1) The stepper positioning is not fix to the place for pusher to stop due to the
used of chain. The pusher have idle before the operation
2) Items unable to dispense from magazine because of the design and the quantity
of items in the packaging.
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CHAPTER 3
PROJECT SUMMARY
3.1 SAFETY FEATURES
As a safety precaution, we have included all the safety equipments to provide the
safety features for our SSRS machine.
Items Safety Reason
1. Emergency Stop Button
Used to cut off the vending machine power supplyto stop all process when any accidents occur.
2. Circuit Breaker
Use Earth Leakage Circuit Breaker and MiniatureCircuit Breaker to cut off leakage current.
3. Control Panel Box Use as the container for the wiring andconnection. It can keep away from human reach.
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4. Tower Lamp
Use to indicate the process that been running bythe machine.
5. Safety Precaution Notice
Use to let user used the machine appropriatelyand safely.
Table: Safety items provided for SSRS.
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3.2 INSTRUMENTS, EQUIPMENTS AND ENGINEERING COST
3.2.1 MECHANICAL COMPONENT
PURCHASED
NO. ITEMS QUANTITY PRICE PERUNIT(RM)
TOTAL(RM)
1. Aluminum Profile 40x40mmx5m 7pcs 47.00/m 1645.00
2. Gusset Element 40x40mm 50pcs 5.50 275.00
3. Hammer Head Screw M8x20 50pcs 3.00 300.00
4. Flange Nut M8 100pcs 0.30 30.00
5. Block with Flange 2pcs 350.00 700.00
6. Slotted Block 3pcs 49.00 147.00
7. End Cap 8pcs 2.50 20.00
8. Magnetic Lock 3pcs 16.70 50.10
9. Left Hinge 4pcs 6.40 25.6010. Right Hinge 4pcs 6.40 25.60
11. Liromat Handle 3pcs 9.90 29.70
12. Mild Steel Container:i) 403x57x17mmii) 403x27x62mmiii) 403x92x27mmiv) 403x102x27
mmv) 403x112x27mmvi) 403x122x47mmvii) 403x141x47mmviii) 403x141x47
1pcs1pcs1pcs1pcs1pcs1pcs1pcs
1pcs1pcs1pcs1pcs1pcs1pcs1pcs1pcs
75.0075.0075.0085.0085.0095.0095.00
95.0095.00100.0095.0095.0095.00
105.00105.00
75.0075.0075.0085.0085.0095.0095.00
95.0095.00100.0095.0095.0095.00105.00105.00
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mmix) 403x141x47mmx) 403x152x52mm
xi) 403x154x42mmxii) 403x154x42mmxiii) 403x154x42mmxiv) 403x172x32mmxv) 403x172x32mmxvi) 403x204x27
mmxvii) 603x92x32mmxviii) 403x306x226mmxix) 403x306x226mmxx) 403x306x226mm
1pcs1pcs1pcs1pcs1pcs
110.0075.00
145.00145.00145.00
110.0075.00145.00145.00145.00
13. Acrylic Sheet:i) 3x1000x1700mmii) 3x1000x1000mm
4pcs2pcs
170.00128.00
680.00256.00
NO. ITEMS QUANTITY PRICE PERUNIT(RM)
TOTAL(RM)
14. Aluminum Plate:i) 1x1220x350mmii) 8x250x320mmiii) 1x60x1220mmiv) 10x20x880mmv) D=12.7x300mm
1pcs1pcs2pcs1pcs2pcs
32.0077.006.50
24.004.50
32.0077.0013.0024.009.00
15. Angle Iron (L) 30x30x3x600mm 18pcs 8.00 144.00
16. U Beam 30x1000x1700mm 5pcs 13.00 65.00
TOTAL (RM) 6538.00
Table: Purchased mechanical component.
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RECYCLED
NO. ITEMS QUANTITY PRICE PERUNIT(RM)
TOTAL(RM)
1. Aluminum Profile 40x40mmx5m 3pcs 47.00/m 141.00
2. Gusset Element 40x40mm 30pcs 5.50 165.003. Gusset Element 20x28mm 30pcs 4.50 135.00
4. Gusset Element 20x20mm 4pcs 7.20 28.80
5. Hammer Head Screw M8x20 30pcs 3.00 90.00
6. Flange Nut M8 30pcs 0.30 9.00
7. Liromat Handle 3pcs 9.90 29.70
8. Right Hinge 2pcs 6.40 12.80
9. Left Hinge 2pcs 6.40 12.80
10. Caster Wheel 4pcs 8.00 32.00
11. Black Strip (L=2m) 5pcs 5.20 26.00
TOTAL (RM) 682.10
Table: Recycled mechanical component.
MISCELLANEOUS
NO. ITEMS QUANTITY PRICE PERUNIT(RM)
TOTAL(RM)
1. Chain Detach 1pcs 20.00 20.00
2. Screw and Nut 100pcs 0.15 15.00
3. Sand paper 2pcs 2.00 2.00
4. Drill Bit (3.3mm) 1pcs 1.00 1.00
5. Grinder 1pcs 3.00 3.00
6. Sand Paper 3pcs 0.66 2.00
7. Screw and Nut 30pcs 0.25 7.50
8. Grinder 2pcs 2.65 5.30
9. Door Lock 2pcs 0.80 1.60
10. Spray Grey 6pcs 6.00 36.00
11. RS 35 Cable Link 8pcs 3.20 25.60
12. TOYO Grease 1pcs 8.50 8.50
13. Mild Steel Plate:
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i) 4.5x40x40mmii) 6x104x114mmiii) 6x100x96mmiv) 6x44x34mmv) 4.5x844x44mm
vi) 4.5x44x1024mmvii) 4.5x44x1004mm
16pcs1pcs2pcs6pcs4pcs
2pcs4pcs
1.504.003.001.50
10.00
12.0011.90
24.004.006.009.00
40.00
24.0047.60
14. Shaft:i) 10x500mmii) 10x150mmiii) 10x260mmiv) 10x60mm
1pcs1pcs4pcs2pcs
2.000.601.000.30
2.000.604.000.60
15. Aluminum Plate(0.7mmx4inchx8inch) 1pcs 100.00 100.00
16. ISC Fabrication (Slotted Block) 6pcs 15.00 90.00
17. Welding mechanical part - - 100.00
18. RS35 QCM Roller Chain 10FT 4.00/FT 40.0019. Gear (14 tooth) 16pcs 8.00 128.00
20. Gear (27 tooth) 1pcs 14 14.00
21. 628 ZZ ZYZ Bearing 26pcs 3.00 78.00
22. 6000 ZZ KDYD Bearing 16pcs 3.00 48.00
23. RS35 CONN LINK 5pcs 2.50 12.50
24. RS35 Roller Chain 10FT 3.50/FT 35.00
25. SOC Sec Screw M4x16 Cup 30pcs 0.10 3.00
26. Flat HD SOC Screw M8x35 35pcs 0.26 9.10
27. Hex Nut M8 Black 55pcs 0.038 2.10
28. MS Flat Washer M8 105pcs 0.028 3.00
29. MS Flat Washer M5 50pcs 0.01 0.50
NO. ITEMS QUANTITY PRICE PERUNIT(RM)
TOTAL(RM)
30. SOC HD Cap Screw M6x16 30pcs 0.073 2.20
31. Hex Nut M6 Black 80pcs 0.025 2.00
32. MS Flat Washer M6 20pcs 0.025 0.50
33. SOC HD Cap Screw M6x20 30pcs 0.08 2.40
34. SOC HD Cap Screw M8x20 30pcs 0.15 4.50
35. Flat HD SOC Screw M8x16 10pcs 0.16 1.60
36. Hex Nut M8 20pcs 0.05 1.0037. MS Flat Washer M12 20pcs 0.06 1.20
TOTAL (RM) 967.90
Table: Miscellaneous mechanical component.
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3.2.2 ELECTRICAL COMPONENTS
PURCHASED
NO. ITEMS QUANTITY PRICE PERUNIT(RM)
TOTAL(RM)
1. Cable Tie 4” 100pcs 1 pack 6.00 6.00
2. Selector Switch ON/OFF 1pcs 23.00 23.00
3. Emergency Push Button NC 1pcs 24.80 24.804. PVC Trunking Grey (L=3m) 1pcs 10.50 10.50
5. DC motor 12V 1pcs 55.00 55.00
6. Tower Lamp 240 VAC 3 Indicator 1pcs 120.00 120.00
7. Cable Tie Marker 1 pack 39.00 39.00
8. Power Supply 12V, 24 VDC,4.5A 2pcs 150 300.00
9. OMRON Relay-MY2 DC 24 or
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12V 5pcs 38.00 190.00
10. Limit Switch OMRON 4 4.50 18.00
TOTAL (RM) 786.30
Table: Purchased electrical component.
RECYCLED
NO. ITEMS QUANTITY PRICE PERUNIT(RM)
TOTAL(RM)
1. DC motor 12V 1pcs 55.00 55.00
2. Stepper Motor 1pcs 2650.00 2650.00
3. Motor Driver 1pcs 1260.00 1260.00
4. PC I/O card c/w Terminal Block 1pcs 1600.00 1600.005. Inductive sensor 1pcs 150.00 150.00
6. Terminal Block 35pcs 0.90 31.50
7. MCB 2pcs 3.80 7.60
8. ELCB 1pcs 48.00 48.00
TOTAL (RM) 5802.10
Table: Recycled electrical component.
MISCELLANEOUS
NO. ITEMS QUANTITY PRICE PERUNIT(RM)
TOTAL(RM)
1. 2 Pin Multi Plug 1pcs 4.80 4.80
2. 4N25 2pcs 2.00 4.00
3. CON 5A Connector 8pcs 1.40 11.20
4. PCB Board 2pcs 5.50 11.00
5. Cable Lug (100pcs) 2pkt 0.10 20.00
6. SD 10/C-Green Switch 1pcs 3.00 3.007. SD 10/C-Red Switch 1pcs 3.00 3.00
8. MYRO Switch 4pcs 4.00 16.00
9. 4N25 I/C Stand 16pcs 1.50 24.00
10. PCB Board 1pcs 1.80 1.80
11. LED 24 VDC S722C 16pcs 2.50 40.00
12. Magnetic Switch 5pcs 5.00 25.00
13. IC Opto Coupler 4N25 16pcs 0.30 4.80
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14. RS35X14TXIR 13pcs 8.00 114.00
15. RS35X27XIR 1pcs 17.00 17.00
16. Terminal Block 95pcs 0.90 85.50
17. Din Rail 2m 5.50/m 11.00
18. PIN 1.25 AF 100pcs 0.13 13.00
19. SN 30 Stand 12pcs 0.90 10.8020. Wiring Duct 2m 9.00/m 18.00
21. Cable Lug Pin (100pcs) 2pkt 12.00/pkt 24.00
22. 3 Pin Socket 1pcs 3.00 3.00
23. MDO Wiring Duct 1m 8.00/m 8.00
24. ZPS 6A SP MCB 2pcs 3.80 7.60
TOTAL (RM) 480.50
Table: Miscellaneous electrical component.
3.2.3 TOTAL COSTING
For the total costing, we have concluded with the purchase, recycled and
miscellaneous components. As shown below is the total cost for the Mechanical and
Electrical components.
MECHANICAL:
Purchase: RM 6538.00
Recycled: RM 682.10
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Miscellaneous: RM 967.90
TOTAL: RM 8188.00
ELECTRICAL:
Purchase: RM 786.30
Recycled: RM 5802.10
Miscellaneous: RM 480.50
TOTAL: RM 7068.90
Total Project Cost = Mechanical Components + Electrical Components
Total Project Cost = RM 8188.00 + RM 7068.90
= RM 15,256.90
3.3 CONCLUSION
We can conclude this project does have a lot to offer in terms of the design, cost,
and ability. Besides that, it generates opportunities for the student to develop practical
ability besides gaining a lot of knowledge and information concerning in technical.
This project emphasizes teamwork spirit among students besides being punctual in
completing the task in the given period of time. Therefore, punctuality and teamwork
among the students can be inculcated. It also develops a good relationship among the
group members.
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Beside that, we can save a lot of time and money. By completing all the
implementation of the project, each member of the group will get benefit and deserve
some credit as pointed below:-
i. Able to design a machine that can organize the stationary merchandise.
ii. Able to develop a system that fully controlled by computer base.
iii. Able to develop an efficient office management by equip the latest technology
for monitoring system.
iv. Able to improve inventory system and simulate the industrial practices on
realistic industrial system model.
The project introduces a new alternative in industrial automation. In the future,
people can adopt the knowledge and refer to the concept especially in STATIONARY
STORAGE AND RETRIEVAL SYSTEM. It is also gives a foresight view in application of
PLC, Mechanical Electrical and Computer programming. Lastly, we are pleased that our
project can be implemented successfully.
3.4 RECOMMENDATION
Due to this prototyping project, we have overlooked to improvise this project in the
future. Stated below is the recommendation and improvisation to this project:
1) The positioning chain, it can be replaced with belting
2) The used of gear can be replaced by the usage of timing pulley
3) The usage of PC to store and retrieve the database can be improvise by
replacing it with industrial touch panel
4) The material of the magazine can be substitute with acrylic, so it is lighter.
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Proposed Gantt Chart
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Reviewed Gantt Chart
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Project Progress Report
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Vendor data
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Appendix 5: Layout view for all parts of SSRS.
5.1 Base of SSRS.
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5.2 Silo and discharge section of SSRS.
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5.3 Movable drawer for upper container of SSRS.
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5.4 Movable drawer for bottom container of SSRS.
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5.5 Upper and lower Pusher section of SSRS.
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5.6 Stepper section of SSRS.
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5.7 Positioning table of SSRS.
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5.8 Bearing flange of SSRS.
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5.9 Magazine for A4 and writing paper of SSRS.
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5.10 Magazine for red, blue and black marker of SSRS.
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5.11 Magazine for blue and black marker of SSRS.
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5.12 Magazine for stapler bullet of SSRS.
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5.13 Magazine for paper clips of SSRS.
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5.14 Magazine for stapler of SSRS.
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5.15 Magazine for thumb tack of SSRS.
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5.16 Magazine for red, blue and black ink refill of SSRS.
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5.17 Magazine for fastener of SSRS.
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5.18 Magazine for memo pad of SSRS.
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Initial Condition
Step 1
M 0.0
Step 2
M 0.2
Step 3
M 11.0
Step 4
M 11.1
I 1.4
I 1.4
T 37
I 2.6
I 2.5Q 0.0
I 2.5
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 1 Extend
Pusher 1 Retract
Position 1 : Stapler
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Initial Condition
Step 1
M 0.0
Step 2
M 0.3
Step 3
M 11.0
Step 4
M 11.1
I 0.2
I0.2
T 38
I 2.6
I 2.5Q 0.0
I 2.5
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 1 Extend
Pusher 1 Retract
Position 2 : Paper Fastener
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Initial Condition
Step 1
M 0.0
Step 2
M 0.4
Step 3
M 11.0
Step 4
M 11.1
I 1.5
I 1.5
T 39
I 2.6
I 2.5Q 0.0
I 2.5
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 1 Extend
Pusher 1 Retract
Position 3 : Writing Pad
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Initial Condition
Step 1
M 0.0
Step 2
M 0.5
Step 3
M 11.0
Step 4
M 11.1
I 1.6
I 1.6
T 40
I 2.6
I 2.5Q 0.0
I 2.5
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 1 Extend
Pusher 1 Retract
Position 4 : Memo Pad
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Initial Condition
Step 1
M 0.0
Step 2
M 0.6
Step 3
M 11.0
Step 4
M 11.1
I 1.7
I 1.7
T 41
I 2.6
I 2.5Q 0.0
I 2.5
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 1 Extend
Pusher 1 Retract
Position 5 : Thumb Tacks
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Initial Condition
Step 1
M 0.0
Step 2
M 0.7
Step 3
M 11.2
Step 4
M 11.3
I 1.0
I 1.0
T 42
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 6 : Marker Ink Refill - Red
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Initial Condition
Step 1
M 0.0
Step 2
M 1.0
Step 3
M 11.2
Step 4
M 11.3
I 1.1
I 1.1
T 43
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 7 : Marker Ink Refill - Blue
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Initial Condition
Step 1
M 0.0
Step 2
M 1.1
Step 3
M 11.2
Step 4
M 11.3
I 0.0
I 0.0
T 44
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 8 : Marker Ink Refill - Black
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Initial Condition
Step 1
M 0.0
Step 2
M 1.2
Step 3
M 11.2
Step 4
M 11.3
I 0.4
I 0.4
T 45
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 9 : Bullet For Stapler
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Initial Condition
Step 1
M 0.0
Step 2
M 1.3
Step 3
M 11.2
Step 4
M 11.3
I 0.5
I 0.5
T 46
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 10 : Paper Clips
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Initial Condition
Step 1
M 0.0
Step 2
M 1.4
Step 3
M 11.2
Step 4
M 11.3
I 0.6
I 0.6
T 47
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 11 : Ball Pen - Blue
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Initial Condition
Step 1
M 0.0
Step 2
M 1.5
Step 3
M 11.2
Step 4
M 11.3
I 0.7
I 0.7
T 48
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 12 : Ball Pen - Black
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Initial Condition
Step 1
M 0.0
Step 2
M 1.6
Step 3
M 11.2
Step 4
M 11.3
I 1.2
I 1.2
T 49
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 13 : A4 Paper
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Initial Condition
Step 1
M 0.0
Step 2
M 1.7
Step 3
M 11.2
Step 4
M 11.3
I 1.3
I 1.3
T 50
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 14 : Marker Pen - Red
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Initial Condition
Step 1
M 0.0
Step 2
M 2.0
Step 3
M 11.2
Step 4
M 11.3
I 0.1
I 0.1
T 51
I 2.4
I 2.3Q 0.3
I 2.3
NS
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Pusher 2 Retract
Position 15 : Marker Pen - Blue
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Initial Condition
Step 1
M 0.0
Step 2
M 2.1
Step 3
M 11.2
I 0.3
I 0.3
T 52
I 2.4
I 2.3
NS
NS
NS
Stepper Motor Enable
Positioning Table Rotate
Pusher 2 Extend
Position 16 : Marker Pen - Black