Stationery Storage and Retrieval System

8/9/2019 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.

German-Malaysian Inst i tute

Training for Advanced Technology

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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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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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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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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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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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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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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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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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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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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




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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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




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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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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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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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.



FRONT VIEW

Diagram 22 : Figure of 3D and actual front view for SSRS.



SIDE VIEW

Diagram 23 : Figure of 3D and actual side view for SSRS.



TOP VIEW

Diagram 24 : Figure of 3D and actual top view for SSRS.



2.1.2 ELECTRICAL WIRING DIAGRAM

Diagram 25 : Figure of electrical wiring diagram for SSRS.



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)



OPTO COUPLER (M5) OPTO COUPLER (N5) OPTO COUPLER (O5)

OPTO COUPLER (P5)

Diagram 26 : Figures of opto-coupler wiring for SSRS.



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.



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.



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.



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



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



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



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



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



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



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



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



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



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



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



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.



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.



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.



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



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


TOTAL(RM)

14. Aluminum Plate:i) 1x1220x350mmii) 8x250x320mmiii) 1x60x1220mmiv) 10x20x880mmv) D=12.7x300mm


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.



RECYCLED


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


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:



i) 4.5x40x40mmii) 6x104x114mmiii) 6x100x96mmiv) 6x44x34mmv) 4.5x844x44mm

vi) 4.5x44x1024mmvii) 4.5x44x1004mm


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



TOTAL(RM)

30. SOC HD Cap Screw M6x16 30pcs 0.073 2.20

31. Hex Nut M6 Black 80pcs 0.025 2.00




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.



3.2.2 ELECTRICAL COMPONENTS

PURCHASED


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



12V 5pcs 38.00 190.00

10. Limit Switch OMRON 4 4.50 18.00

TOTAL (RM) 786.30

Table: Purchased electrical component.

RECYCLED


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


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



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



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.



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.





Proposed Gantt Chart



Reviewed Gantt Chart



Project Progress Report



Vendor data



Appendix 5: Layout view for all parts of SSRS.

5.1 Base of SSRS.



5.2 Silo and discharge section of SSRS.



5.3 Movable drawer for upper container of SSRS.



5.4 Movable drawer for bottom container of SSRS.



5.5 Upper and lower Pusher section of SSRS.



5.6 Stepper section of SSRS.



5.7 Positioning table of SSRS.



5.8 Bearing flange of SSRS.



5.9 Magazine for A4 and writing paper of SSRS.



5.10 Magazine for red, blue and black marker of SSRS.



5.11 Magazine for blue and black marker of SSRS.



5.12 Magazine for stapler bullet of SSRS.



5.13 Magazine for paper clips of SSRS.



5.14 Magazine for stapler of SSRS.



5.15 Magazine for thumb tack of SSRS.



5.16 Magazine for red, blue and black ink refill of SSRS.



5.17 Magazine for fastener of SSRS.



5.18 Magazine for memo pad of SSRS.



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



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



Pusher 1 Extend

Pusher 1 Retract

Position 2 : Paper Fastener



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



Pusher 1 Extend

Pusher 1 Retract

Position 3 : Writing Pad



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



Pusher 1 Extend

Pusher 1 Retract

Position 4 : Memo Pad



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



Pusher 1 Extend

Pusher 1 Retract

Position 5 : Thumb Tacks



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



Pusher 2 Extend

Pusher 2 Retract

Position 6 : Marker Ink Refill - Red



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



Pusher 2 Extend

Pusher 2 Retract

Position 7 : Marker Ink Refill - Blue



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



Pusher 2 Extend

Pusher 2 Retract

Position 8 : Marker Ink Refill - Black



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



Pusher 2 Extend

Pusher 2 Retract

Position 9 : Bullet For Stapler



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



Pusher 2 Extend

Pusher 2 Retract

Position 10 : Paper Clips



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



Pusher 2 Extend

Pusher 2 Retract

Position 11 : Ball Pen - Blue



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



Pusher 2 Extend

Pusher 2 Retract

Position 12 : Ball Pen - Black



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



Pusher 2 Extend

Pusher 2 Retract

Position 13 : A4 Paper



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



Pusher 2 Extend

Pusher 2 Retract

Position 14 : Marker Pen - Red



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



Pusher 2 Extend

Pusher 2 Retract

Position 15 : Marker Pen - Blue



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



Pusher 2 Extend

Position 16 : Marker Pen - Black

Stationery Storage and Retrieval System

Documents