1. A utonomous W arehouse F orklift U tilization L ayout Michael F. Maher vs. Peter A. Zarcone

2. Overview Project Description Layout Hardware Software Achievement Goals Testing/Expected Problems Questions

3. The Automated Warehouse Two autonomous forklifts employed to load uniform pallets Producer loads bay from receiving zone Consumer loads shipping zone from bay Sensors used to follow paths Microcontroller used to: –control robot sequencing –control robot performance

4. Storage bay 2 rows by 4 columns Pressure switches in each bay

5. Floor Plan Black floor –Approx. 4’ x 5’ 1 way storage bay –Approx. 2’ x 1’ x.5’ Conveyors Guiding tracks – at critical areas Stow and wait zone –communication interface

6. Robot Communication Communication occurs: –at the Stow and Wait Zone –through a wired interface zero insertion force becomes a critical area Robot is told: –the nearest bay destination –whether a pallet is ready

7. Robot Structure Chassis –1 total Motors –3 total Gears –1 gear rack and 1 gear Sensors –9 total

8. Chassis Built from scratch from: –an old erector set –various hardware components Built around rear drive axle Front ball castors 8 1/2” x 11” x 6” wide

9. Motors/Gears Sayama Geared Motor RB-35CMF JX8 5803 –12 VDC –20mA no-load current draw –<50mA stall current draw –~10RPM @ 12v approx. velocity 1.5”/s 2 drive motors / 1 lift motor 32 pitch 12” gear rack and 3/4” gear

10. Sensors Opto reflectors – QRB1114 –2 for maintaining path accuracy –1 for turn point identification –4 for fork height determination –2 for shaft encoding Daylight filter Black/White distinction

11. Computation 1 PAL –Calculate nearest available bay slot –Box ready for pickup –Path clear 2 Motorolla HCS12 –Wanted to implement states on PALs –Needed PWM for motor speed control

12. Execution Sequence

13. Cost Analysis

14. Progress Report

15. Testing and Foreseen Issues Testing will run concurrent to development –Power –Motor –Sensor –Track accuracy –Vehicle stability Toddler reactive tests Noise and false positive sensor response Closed loop speed control Error state shutdown contingency

16. Goals Provide for customer –Economic solution –Reliable solution Provide for Safety –Training –Human Cost of operating forklifts Veteran drivers

17. Questions APPLAUSE