Graduation Final Book 2

Arab Academy for Science, Technology and Maritime
Transport
College of Engineering and Technology
Mechatronics Engineering
B. Sc. Final Year Project
Design and implementation of smart warehouse
Presented By:
Omar Mohamed Nour Eldien
Amr Sameh Khalaf
Asser Safwat hussien toktomosh
Ahmed Tarek Mohamed
Mostafa Mahmoud Mohamed
Mostafa Mohamed Mahmoud Hassan
Supervised By:
Dr. Tamer Ismael
J u l y 2 0 2 3
DECLARATION
I hereby certify that this material, which I now submit for assessment on the programme
of study leading to the award of Bachelor of Science in (insert title of degree for which
registered) is entirely my own work, that I have exercised reasonable care to ensure that
the work is original, and does not to the best of my knowledge breach any law of
copyright, and has not been taken from the work of others save and to the extent that
such work has been cited and acknowledged within the text of my work.
Signed: Omar Mohamed Nour El Dien
Registration No.: 17104346
Signed: Amr Sameh Khalaf
Signed: Asser Safwat Hussien Toktomosh
Signed: Ahmed Tarek Mohamed
Signed: Mostafa Mahmoud Mohamed
Signed: Mostafa Mohamed Mahmoud Hassan
Date: Wednesday, 11 January 2023.
JULY 2023
ACKNOWLEDGMENT
Special gratitude and thanks to our supervisor Dr. Tamer Ismael for the huge support
they gave us throughout the semester. Their valuable instructions and knowledge guided
us to start this project from scratch. We are grateful that they always give us their time
to help us whenever we need them. Also, we would like to thank the faculty staff all our
professors and teaching assistants for the aid and guidance to become better engineers.
JULY 2023
ABSTRACT
A method of more efficient management that generates a variety of rewards is smart

warehousing. It may serve companies in optimizing their supply chain and giving them
the facilities, they require to increase productivity. Smart warehouse technologies are
designed to offer businesses real-time visibility, allowing them to manage processes and
make quick adjustments to speed up operations. Additionally, our main objectives in
this project decreasing human mistake and improve facility security and safety, and the
capacity of a smart warehouse to save the business time and money, enhance
profitability, and improve client and customer happiness are often its main advantages.
The objective of this project is to identify, evaluate, and synthesize the relevant studies
discussing the design of smart warehouses and the transition to these new types of
warehouses. The challenges of smart warehousing are highlighted as the fulfilment and
delivery operations of many supply chains are now dependent on high degrees of
automation.
JULY 2023
TABLE OF CONTENTS
LIST OF FIGURES ................................................................................................................................... III
LIST OF TABLES ......................................................................................................................................VI
LIST OF ACRONYMS/ABBREVIATIONS .......................................................................................... VII
LIST OF UTILIZED STANDARDS ..................................................................................................... VIII
LIST OF REALISTIC CONSTAINTS ...................................................................................................... X
1 INTRODUCTION .................................................................................................................................. 1
2 LITERATURE REVIEW AND BACKGROUND .............................................................................. 3
2.1 Introduction ................................................................................................................. 3

2.2 Amazon warehouse: ..................................................................................................... 4
2.2.1 ROBOTICS SYSTEM: ........................................................................................................... 6
2.2.2 SOFTWARE: .......................................................................................................................... 8
2.2.3 SOME OF THE KEY FEATURES OF AMAZON’S SMART WAREHOUSES ................ 13
2.3 Smart warehouse workflow and architecture .......................................................... 13
2.3.1 WORKFLOW ....................................................................................................................... 13
2.3.2 RFID TECHNOLOGY .......................................................................................................... 18
2.3.3 AUTOMATED STORAGE AND RETRIVAL SYSTEM ................................................... 22
2.3.4 TYPES OF AUTOMATED GUIDED VEHICLES .............................................................. 29
3 METHODOLOGY............................................................................................................................... 39
3.1 Introduction ............................................................................................................... 39

3.2 anylogic software........................................................................................................ 39
3.3 CONTROL ................................................................................................................. 41
3.3.1 PROCESS FLOWCHART .................................................................................................... 42
3.4 OBJECTIVES ............................................................................................................ 43
4 SIMULATION ..................................................................................................................................... 44
4.1 INTRODUCTION ...................................................................................................... 44

4.2 ARCHITECTURE LAYOUT ................................................................................... 44
4.3 MAIN COMPONENTS OF THE SIMULATION ................................................... 45
4.4 ENITIES ..................................................................................................................... 47
4.5 WORKFLOW AND PROCESS ................................................................................ 52
5 LIST OF COMPONENTS AND DESIGN ......................................................................................... 53
5.1 LIST OF COMPONENTS ......................................................................................... 53

5.2 SENSORS ................................................................................................................... 56
5.3 CONTROL AND CIRCUIT CONNECTIONS ........................................................ 57
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5.4 OPERATIONS ........................................................................................................... 57
5.5 DESIGN ...................................................................................................................... 60
6 CONTROL AND CIRCUIT CONNECTIONS ................................................................................. 62
CONTROL AND CIRCUIT CONNECTIONS ..................................................................... 62
7 CONCLUSION AND DISCUSSION .................................................................................................. 63
7.1 INTRODUCTION ...................................................................................................... 63

7.2 RECAPITULATION ................................................................................................. 63
7.3 ACHIVEMENTS AND ADVANTAGES .................................................................. 63
7.4 IMPACT ON SUPPLY CHAIN ................................................................................ 64
7.5 CHALLENGES AND CONSIDERATIONS ............................................................ 64
7.6 FUTURE OUTLOOK ................................................................................................ 65
7.7 CONCLUSION .......................................................................................................... 65
7.8 APPENDIX ................................................................................................................. 66
7.9 REFRENCES ............................................................................................................. 67
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LIST OF FIGURES
Figure 1-1 Robots in a smart warehouse ........................................................................................1

Figure 1-2 Overview layout for anylogic .......................................................................................2
Figure 2-1 Example of amazon's warehouses ................................................................................3
Figure 2-2 A generic display of the departments in a warehouse ..................................................4
Figure 2-3 The startup of amazon ..................................................................................................5
Figure 2-4 Kiva's robot design .......................................................................................................6
Figure 2-5 Canva's cart ..................................................................................................................7
Figure 2-6 The smart pac machine along with the CMC carton wrap ...........................................7
Figure 2-7 Soft robotics’ robot hand ..............................................................................................8
Figure 2-8 Flowchart of amazon's web services evolution ............................................................9
Figure 2-9 How amazon's S3 was formed ...................................................................................10
Figure 2-10 The change from Oracle to AWS .............................................................................10
Figure 2-11 Robomaker capabilities ............................................................................................11
Figure 2-12 The growth of amazon's warehouses throughout the years ......................................12
Figure 2-13 Unloading docks.......................................................................................................14
Figure 2-14 Robot holding the items to the unloading docks ......................................................15
Figure 2-15 Relationship between publishers and subscribers ....................................................15
Figure 2-16 An overview of how a smart warehouse works .......................................................16
Figure 2-17 RFID warehouse system...........................................................................................17
Figure 2-19 RFID tag ...................................................................................................................18
Figure 2-18 RFID reader ..............................................................................................................18
Figure 2-20 Difference between RFID and barcode ....................................................................18
Figure 2-21 RFID system's process .............................................................................................19
Figure 2-22 Middleware architecture ...........................................................................................21
Figure 2-23 Architecture of RFID tags ........................................................................................21
Figure 2-24 RFID retail 3.0 .........................................................................................................22
Figure 2-25 Typical AS/RS .........................................................................................................22
Figure 2-26 AS/RS.......................................................................................................................23
Figure 2-27 Unit-load AS/RS ......................................................................................................24
Figure 2-28 Mini load AS/RS ......................................................................................................24
Figure 2-29 Vertical lift modules .................................................................................................24
Figure 2-30 Shuttles .....................................................................................................................25
Figure 2-31 Horizontal carousel ..................................................................................................25
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Figure 2-32 Cube based storage ...................................................................................................25
Figure 2-33 Vertical carousels .....................................................................................................26
Figure 2-34 Different types of AGV ............................................................................................28
Figure 2-35 Automated guided cart .............................................................................................29
Figure 2-36 Forklift AGV ............................................................................................................29
Figure 2-37 Towing AGV ............................................................................................................30
Figure 2-38 Unit load AGV .........................................................................................................30
Figure 2-39 Heavy burden AGV ..................................................................................................31
Figure 2-40 Autonomous mobile robot ........................................................................................31
Figure 2-41 Magnetic guide tape navigation ...............................................................................32
Figure 2-42 Laser target navigation .............................................................................................32
Figure 2-43 Inertial (gyroscopic) navigation ...............................................................................33
Figure 2-44 Vision guidance ........................................................................................................33
Figure 2-45 Light detection and ranging......................................................................................34
Figure 2-46 Natural navigation ....................................................................................................34
Figure 2-47 QR code guide ..........................................................................................................35
Figure 3-1 RC car.........................................................................................................................41
Figure 3-2 Process flowchart .......................................................................................................42
Figure 4-2 3D model ....................................................................................................................44
Figure 4-1 2D model ....................................................................................................................44
Figure 4-3 Architecture layout .....................................................................................................45
Figure 4-4 Conveyor belt .............................................................................................................45
Figure 4-5 AGVs transporting items from conveyor belts...........................................................46
Figure 4-6 Pallet racks .................................................................................................................46
Figure 4-7 Anylogic flowchart.....................................................................................................47
Figure 4-8 Source.........................................................................................................................47
Figure 4-9 Convey .......................................................................................................................48
Figure 4-10 MoveByTransporter .................................................................................................48
Figure 4-11 Rack store .................................................................................................................49
Figure 4-12 Queue .......................................................................................................................49
Figure 4-13 Hold ..........................................................................................................................49
Figure 4-14 Seizetransporter ........................................................................................................50
Figure 4-15 Rack pick ..................................................................................................................50
Figure 4-16 Batch ........................................................................................................................50
Figure 4-17 Transporter fleet .......................................................................................................51
Figure 4-18 Rack system .............................................................................................................51
Figure 4-19 Function....................................................................................................................51
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Figure 5-1 AGV prototype ...........................................................................................................53
Figure 5-3 Detailed chassis top view ...........................................................................................53
Figure 5-2 Chassis top view .........................................................................................................53
Figure 5-4 Tyre dimensions .........................................................................................................54
Figure 5-5 DC motor ....................................................................................................................54
Figure 5-6 DC motor specifications .............................................................................................54
Figure 5-7 Battery ........................................................................................................................55
Figure 5-8 H-Bridge.....................................................................................................................55
Figure 5.9 TCRT5000 ..................................................................................................................56
Figure 5-10 Husky lens ................................................................................................................56
Figure 5-11 Connection types ......................................................................................................57
Figure 5-12 Line learning technique ............................................................................................57
Figure 5-13 Line prediction technique .........................................................................................58
Figure 5-14 Different QR codes...................................................................................................58
Figure 5-15 Tag identification .....................................................................................................58
Figure 5-16 Tag detection ............................................................................................................58
Figure 5-17 Tag recognition ........................................................................................................59
Figure 5-18 Step one of learning .................................................................................................59
Figure 5-19 Step two of learning .................................................................................................59
Figure 5-20 Exterior AGV design................................................................................................60
Figure 5-21 AGV's top view and dimensions ..............................................................................60
Figure 5-22 Motor and tyre dimensions .......................................................................................60
Figure 5-23 AGV's exterior cover................................................................................................61
Figure 6-1 AGV circuit ................................................................................................................62
v
LIST OF TABLES
Table 6-1 Specifications ..............................................................................................................62
vi
LIST OF ACRONYMS/ABBREVIATIONS
AI - Artificial Intelligence
IoT - Internet of Things
ML - Machine Learning
DL - Deep Learning
NLP - Natural Language Processing
CV - Computer Vision
ANN - Artificial Neural Network
SVM - Support Vector Machine
RF - Random Forest
RNN - Recurrent Neural Network
CNN - Convolutional Neural Network
LSTM - Long Short-Term Memory
GAN - Generative Adversarial Network
API - Application Programming Interface
GUI - Graphical User Interface
CPU - Central Processing Unit
GPU - Graphics Processing Unit
RAM - Random Access Memory
SSD - Solid State Drive
HDD - Hard Disk Drive
OS - Operating System
IDE - Integrated Development Environment
HTML - Hypertext Markup Language
CSS - Cascading Style Sheets
SQL - Structured Query Language
JSON - JavaScript Object Notation
XML - Extensible Markup Language
HTTP - Hypertext Transfer Protocol
HTTPS - Hypertext Transfer Protocol Secure
API - Application Programming Interface
URL - Uniform Resource Locator
FTP - File Transfer Protocol
DNS - Domain Name System
VPN - Virtual Private Network
SSL - Secure Sockets Layer
TLS - Transport Layer Security
HTML5 - Hypertext Markup Language Version 5
CSS3 - Cascading Style Sheets Version 3
REST - Representational State Transfer
CRUD - Create, Read, Update, Delete
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LIST OF UTILIZED STANDARDS
IEEE 802.11 - Wireless LAN (Wi-Fi) standard

IEEE 802.3 - Ethernet standard
HTML5 - Hypertext Markup Language Version 5
CSS3 - Cascading Style Sheets Version 3
TCP/IP - Transmission Control Protocol/Internet Protocol
HTTP - Hypertext Transfer Protocol
HTTPS - Hypertext Transfer Protocol Secure
JSON - JavaScript Object Notation
XML - Extensible Markup Language
SQL - Structured Query Language
SSL - Secure Sockets Layer
TLS - Transport Layer Security
OAuth - Open Authorization
OAuth2 - Open Authorization version 2.0
OpenID - OpenID Connect
REST - Representational State Transfer
SOAP - Simple Object Access Protocol
WSDL - Web Services Description Language
RDF - Resource Description Framework
OWL - Web Ontology Language
UML - Unified Modeling Language
ISO 27001 - Information Security Management System (ISMS) standard
ISO 9001 - Quality Management System (QMS) standard
ISO 14001 - Environmental Management System (EMS) standard
ISO/IEC 27002 - Code of Practice for Information Security Controls
PCI DSS - Payment Card Industry Data Security Standard
HIPAA - Health Insurance Portability and Accountability Act
GDPR - General Data Protection Regulation
viii
NIST - National Institute of Standards and Technology (various
standards such as NIST SP 800-53, NIST SP 800-171)
IETF - Internet Engineering Task Force (various standards such as RFC
2616, RFC 7540)
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LIST OF REALISTIC CONSTAINTS
Warehouse Dimensions:
AGV Parking , Loading Dock, Unloading Dock 180x300 mm
No. of Storage Unit 10
Storage Unit Dimension/Unit 200x200 mm
Distance from parking to loading 1360 mm
Distance from from loading to storage unit 930 mm
Distance from from storage unit to unloading 1950 mm

Floor space:
Length x width 2600 x2300 m
Drive:
DC motors Size 70 x 22 x 18 mm
Motor Weight 29 gram
Voltage and Current supply 3V-100mA
Car speed/MIN 20 m/Min
Reduction Rate 48:1
Speed 100 RPM
H-Bridge i/p 12 V
Sensors:
TCRT5000 5v
HuskyLens 3.5 v
Power Supply:
Voltage and Current supply 12V-200mA
x
Chapter One
1 INTRODUCTION
Technology is increasingly transforming the way the world looks as we

move toward the future. Industries are being replaced by automation.
Almost every item in a smart warehouse can be controlled with a
single click, and nothing is left unaffected by the powers of
automation. Automation based on the Internet of Things (IoT) provides
a wide variety of applications and is the primary technology driving
the industry 4.0 revolution. The Internet of Things (IoT) is a network
of automated systems that enables users to manage and coordinate
things within the Internet's mesh. It serves in devolving command and
control. The Industrial Internet of Things (IOT) is converting
traditional industrial processes into Cyber-Physical Systems (CPSs) in
this era of industry's advancement into the digital world. Industry 4.0
technologies seek to do tasks more efficiently and more reliably in less
time, from manually moving and managing large things to automating
operations. In the manufacturing of any industrial system as well as the
industry supply chain, warehouses are important. Being used to store,
handle, and track the items, a company's warehouse plays a key role in
the smooth operation of the entire business. By allocating a tracking
ID, the arriving products are collected and placed in the appropriate
storage units. Additionally, these tracking IDs are kept with the
product information in a register or electronic database. The data in the
database is updated for the finished goods that need to be delivered
outside of the warehouse against their tracking IDs. The majority of
these duties are carried automatically in most warehouses as shown in
figure 1-1.
Figure 1-1 Robots in a smart warehouse
The robots in the smart warehouse system to communicate with all the
other required equipment and finish their jobs. Smart warehouse is
1
designed to boost productivity and reduce all kind of mistakes. Robots
used to locate and choose things in the most realistic setting shipping.
Main objectives in this project high efficiency and productivity,
choosing fastest routes for ‘AGVs to finish their tasks with time
scheduled, all working ‘AGVS’ finishing tasks/orders simultaneously
without collisions and with high safety for the warehouse, and
improving management by iot.
Smart warehouse contains of:
• (number of racks Hor-Ver)
• (number of AGVs)
• (conveyor belts)
• Sensors
The project working with simulation program Anylogic that provides
an important method of analysis which is easily verified,
communicated, and understood. Across industries and disciplines,
simulation modeling provides valuable solutions by giving clear
insights into complex systems. Through the next section, the evolution
of amazon as well as the technologies, processes, robotic software, and
all classifications of components used inside amazon’s warehouses will
be thrashed out as shown in figure 1-2.
Figure 1-2 Overview layout for anylogic
Chapter Two will be showing the literature review and background

with a lot of information and knowledge which helped us more in
studying warehouses, also workflow and structure of smart warehouse
(features, components).
Chapter Three is discussing the methodology of smart house and our
workflow, showing the software that we are using to simulate the
warehouse with its priority rules.
2
Chapter Two
2 LITERATURE REVIEW AND BACKGROUND
2.1 INTRODUCTION
In this chapter the idea of using a smart architecture with reference to the IOT and
decentralization has been widely discussed in the literature. However, the design of
a reference architecture for warehouse automation is a relatively emerging field. A
summary of various works performed in this context is given below. The
management of a warehouse may consist of managing the goods or products coming
into the inventory, keeping track of the location of the items, and handling the
check-outs of the finished goods. Data collection or data entry is one of the
important aspects of warehouse management. As Smart warehouses from Amazon
are created to be extremely effective and automated spaces for order fulfilment.
They use advanced technologies, including robots and machine intelligence, to
enhance different warehouse processes. Wherever there is discussion about the
supply chain, Amazon is the proverbial elephant in the room. The Amazon impact is
what everyone is pursuing. Everyone is attempting to determine how to live up to
the customer expectations that Amazon and its business methods have raised. It's
challenging to adapt Amazon's techniques or approaches for a different industry.
Amazon is a unique breed of beast in terms of order volume and order profile as
shown in figure 2-1.
Figure 2-1 Example of amazon's warehouses
3
▪ Workflow of warehouse:
In principle, a warehouse is an inventory that may be subdivided into numerous

categories including finished goods, raw material storage, and incoming goods and
services. Racks, boxes, and pallets are typically used in warehouses to store items. It
is separated into a number of parts, each of which is further classified according to
the types of products, sales, and clients. Below are quick summaries of the
individual parts, and the general organization is provided as shown in figure 2-2.
Figure 2-2 A generic display of the departments in a warehouse
2.2 AMAZON WAREHOUSE:
Through this section amazon evolution will be discussed in detail, discussing their
upgrades through years till reach the top and highest technology in warehousing
field.
Since its founding in 1994, as shown in figure 2-3, Amazon.com has been a leader
in retail innovation. Amazon.com invested heavily in technology to improve
distribution in their warehouses and services for their customers as the making
marketing decisions from an online bookstore to the largest retailer in the world.
Kiva Systems was acquired by Amazon.com in 2012, which began their journey
toward automation. Additionally, the business started collaborating with other
suppliers to automate distribution facilities. They have also developed programs to
assist workers who have been replaced by automation by enhancing their education
and skill set. For usage in robotics automation, the corporation has made
investments in cloud computing and storage. Since 2012, Amazon income has
increased by 359% and its workforce by 800%. In 1995, Jeff Bezos, the company's
creator, launched a basic online bookshop out of his garage. Bezos thought that
4
"becoming large fast" was the secret to success. The business rapidly went beyond
selling books to include other consumer goods like music and video at first, and
later in the late 1990s, consumer devices and toys. Since the mid-1990s, the
company's storage capacity has grown from a few shelves in their office in Seattle,
Washington to more than 175 warehouses currently spread throughout North
America and Europe. Because Amazon service includes more than simply storage,
its warehouses are referred to as "Fulfillment Centers." Orders are picked up,
packaged, and sent to clients at fulfilment centers.
Figure 2-3 The startup of amazon
With the public launch of Amazon Web Services in 2006, Amazon.com made its
first significant entrance into the cloud computing industry by enabling businesses
to access the storage and processing capacity of the online retailer. The Fulfillment
by Amazon service, which enables third-party retailers to store their goods at
Amazon.com warehouses and sell through Amazon.com, was introduced about the
same time. As a result of the rising demand, Amazon.com was forced to make
investments in automation to improve the productivity of their Fulfillment Centers.
Kiva Systems, which Amazon.com acquired in 2012 for $775 million and is now
using as the foundation of its automation programmed.
2015 was seeing the renaming of Kiva as Amazon Robotics. Canvas Technology, a
business that creates autonomous cars with computer assisted vision, was purchased
by Amazon.com in 2019. The same year, Amazon.com also started collaborating
with additional suppliers for packing, selecting, and wrapping, including CMC, Soft
Robotics, and Smart Pac.
Amazon has more than 70 distribution centers that have been built recently. These
boast modern infrastructure and technology. They are scattered across the United
States. It makes sense to carry orders to a distribution center located closest to a
customer’s delivery zip code. The system needs to recognize the zip code and
match it to the nearest DC that has the appropriate inventory on the shelf.
Distributed Order Systems (DOM) are available from various WMS vendors and
can add on to an existing WMS or in a new deployment.
5
2.2.1 ROBOTICS SYSTEM:
There is a lot of technology that is working behind the scenes in Amazon

warehouses and much of it may not be visible at first sight. Most of the technologies
used are proprietary and something that Amazon has been working on for long time.
The time to fulfill the order must be minimized. Let’s review below some of the
robotic masterpieces and devices in the warehouse that support this big goal.
• Kiva
When necessary, Amazon deploys a variety of robot arms to grip and transport
goods. The palletizer is the smaller robot, which collects goods off conveyor belts
and places them on pallets. The Robo-Stow, a six-ton robotic arm that can move
pallets of products 7.3 meter between floors, is the biggest robot. The carrying
capacity of the Robo-Stow is 1360 kg as shown in figure 2-4.
Drive units are robots that raise shelves and carry them to workers so they may pick
up and store items.
The DU 1000 drive unit was the first type used when Amazon.com acquired Kiva in
2012.
This robot is 300 mm long, 600 mm wide, and 750 mm long. It can lift roughly 450
kg and weighs 110 kg. It moves at a top speed of 4.68 kilometers per hour. The DU
3000, with a lift capacity of 1,360 kg, is the version for lifting big things. The
Hercules and the Pegasus are two new models that Amazon.com released in 2019.
The Hercules is the replacement for the first drive unit. It is 100 mm shorter, uses
half as many parts, and can lift 226.8 kg more than the original. The difference
between the Pegasus and the Hercules is that the Pegasus has a little conveyor belt
installed on top. A modular robot called the Xanthus has also been unveiled by
Amazon.com. It can have add-ons that let it stack containers or do sorting.
Amazon developed the Robotic Tech Vest to solve the problem of worker safety
when they are on the same floor as the active drive units. Employees had to indicate
areas where they would be working before the Robotic Tech Vest arrived so the
robots would stay away from the space. The robotics system receives a signal from
the vest that marks the region surrounding the worker as an obstruction for the drive
units.
Figure 2-4 Kiva's robot design
6
• Canva
CANVAS Technology, which was established in 2015, is to move items through a

warehouse more efficiently as shown in figure 2-5.
The business launched the CANVAS Cart, an autonomous industrial cart, as their
first product in 2017. It can move by continually creating a 3D map of its
surroundings and transmitting the information to the other carts inside the fleet. As
marks are now used by Amazon drive units to determine their location, the business
purchased CANVAS Technology in 2019 to apply its computer vision technology.
CMC Carton Wrap.
Figure 2-5 Canva's cart
• Smart Pac
The Smart Pac, an automated machine that packages goods in patented envelopes,
the other packaging device used by Amazon.com. When combined with CMC
Carton Wrap, these labor-saving techniques can reduce the number of packers by
more than half as shown in figure 2-6.
Figure 2-6 The smart pac machine along with the CMC carton wrap
7
• Soft Robotics
Amazon.com is continually attempting to advance technologies for grabbing things.

The business has put numerous grippers, including those from Soft Robotics to the
test. A Boston-area start-up called Soft Robotics creates robotic hands that like
octopuses and can precisely select and position objects as shown in figure 2-7.
Figure 2-7 Soft robotics’ robot hand
2.2.2 SOFTWARE:
Amazon inventory management software lets the inventory store only needs;
nothing more, nothing less. Additionally, it sends alerts about packaging,
manufacturing, and pricing changes. Throughout the process, the software acts as a
guide and simplifies trading. Utilizing inventory management software can result in
drastic growth for retailers. Managing your inventory more efficiently with
advanced inventory management software designed for Amazon.
• Amazon Web Services
AWS was first developed in 2000 as a concept for an e-commerce service to help
other suppliers build shopping websites using Amazon's infrastructure. In 2006, the
concept evolved into Amazon Elastic Compute Cloud (EC2), the first AWS service.
Any business may access EC2, a web service, to use Amazon's computing resources
for their own applications. Simple Storage Service (S3), a service that allows
businesses to store and retrieve data uploaded to the AWS cloud, is the second key
element of AWS that was introduced at launch. Amazon Linux was the operating
system used when EC2 first started, but it has since grown to handle a wide range of
OSs, including Windows.
8
Using a cloud computing service has several advantages, including the ability to pay
only for the data that is used, the benefit of cost savings, not having to worry about
capacity or data centre upkeep, and speed. AWS has expanded from providing
compute and storage services to offering a large number of products tailored for
particular use cases, such as analytics, AR/ VR, cost management, block chain,
content streaming, databases, Internet of Things (IOT), machine learning, media,
security, and robotics.
• Evolution of Amazon Web Services
Since its beginning, Amazon has depended on Oracle database software for data
management. Data was routinely backed up by the corporation using scripts and
Oracle Recovery Manager (RMAN) to magnetic tape, which was then managed and
maintained by robots in the on-site tape library. Tape backups would be transported
to a location off-site for storage.
As indicated, RMAN would automatically back up the data, check its integrity, and
then update the catalogue to reflect any changes. The tape-based database system
increased in expense and complexity as Amazon.com grew. With the introduction of
Oracle Database 10g, new capabilities were added that allowed Amazon.com to
backup Oracle databases to Amazon S3, an AWS cloud storage service as shown in
figure 2-8.
Figure 2-8 Flowchart of amazon's web services evolution
The company initially tested whether shifting to cloud storage would be more
effective than the tape-based solution. They discovered that Amazon S3 cloud
storage did not have the significant cost associated with tape's hardware, software
license, or physical storage space. In order to install new hardware, tape storage
must be manually moved and then reinstalled. A person would need to fix the
hardware issue and locate the appropriate tapes to mount. They examined security,
costs, administrator difficulty, availability, and durability to determine whether
changing to Amazon S3 would be beneficial as shown in figure 2-9.
9
They came to the conclusion that utilizing Amazon S3 would enable the company to
save $1 million annually, and that cloud backup and restoration operations were
quicker than those involving tape. As illustrated 50% of backups were transferred to
S3 by October 2011, and 85% of databases were using S3 by August 2012.
Figure 2-9 How amazon's S3 was formed
The backup solution was only one part of the transition to Amazon Web Services.
As seen in Fig. , Amazon started switching from Oracle database software to AWS
between 2013 and 2014. The biggest problem Oracle ran into was that it could not
grow to satisfy Amazon's demands as shown in figure 2-10.
The company recognized that its database administrators were spending too much
time handling hardware, licensing, and just keeping the system operational. Amazon
finished switching their database from Oracle to AWS in October 2019. 75
petabytes of data from 7,500 Oracle databases were transferred by the organization
to a variety of AWS services and Relational Database Service (RDS). Each team
might select the AWS service that would be most effective. The transfer provided
several advantages, including a 60% reduction in database expenses, a 40%
reduction in latency, and a 70% reduction in administrative overhead.
Figure 2-10 The change from Oracle to AWS
• AWS RoboMaker
RoboMaker, one of the AWS services, enables programmers to build, test, and
deploy robotic applications. The service integrates apps with AWS services like
analytics and machine learning using the open-source Robot Operating System
10
(ROS) as the basis. RoboMaker gives programmers the tools they need to make
difficult tasks like processing sensor data, moving on their own, and object and
language recognition simpler. The solution offers the ability to manage fleets for
remote deployment, simulate tasks and motions, and test robots in a development
environment. Robots may be tested in pre-built settings using the AWS simulation
environment, which supports running several simulations at once following that,
using AWS IOT Greengrass, the robotic apps may be wirelessly distributed to the
robot. Companies like Stanley Black & Decker, Robot Care Systems, and NASA all
use RoboMaker as shown in figure 2-11.
Construction robots are trained by Stanley Black & Decker using this service. To
teach autonomous ground vehicles and autonomous vehicles to operate through the
environment, data from sensor technology is used to create 3d models of building
sites. With the guidance of RoboMaker, Robot Care Systems developed a smart
walker that can navigate obstacles, respond to voice instructions, and connect
elderly and disabled people to family members and doctors RoboMaker allows for
companies to quickly create and deploy robotic applications without having to build
a custom infrastructure for the applications requirements.
Figure 2-11 Robomaker capabilities
• Investments and trends
An Amazon Robotics Innovation Hub is a new building that Amazon.com proposes

to invest $40 million into. It is scheduled to launch in 2021. In addition to the 4,000
skilled jobs in the state, the 350,000 sq ft facility in Westborough, Massachusetts is
predicted to generate 200 manufacturing and technology. The Amazon Robotics
Innovation Hub would be the first one specifically devoted to the robotics
programmed among Amazon 18 Tech Hubs in North America as of 2019. Since
buying Kiva in 2012, Amazon.com had grown by 700,000 employees, or 800%, and
opened 149Fulfillment Centers, as shown in Figs, respectively. The company is
expected to open an additional 33 warehouse locations in the US as of January 2020,
as shown in Fig. 3. The company is also planning to use automation to solve the
“last mile” issue of delivery.
11
In 2019, testing began on an autonomous delivery vehicle known as Scout. The 6-
wheeled Scout carries one package to the customer’s home. In 2020, Amazon.com
won a patent for a delivery vehicle that carries multiple customer’s orders. The
lockers on this vehicle are unlocked by using a security code sent to the customer’s
mobile phone. The company also had purchased Zoox, a self-driving vehicle start-
up for over $1.2 billion as shown in figure 2-12.
Figure 2-12 The growth of amazon's warehouses throughout the years
• Conclusion
Amazon success is a result of their great motivation to develop in the field of

automation. After acquiring Kiva System in 2012, the business started developing
and using a variety of autonomous robots, such as the Palletizer, Robo-Stow, and
other drive unit variations. With the acquisition of CANVAS Technology, which
would be used to develop new driving robots with enhanced vision systems, the
company continued to innovate. Additionally, Amazon.com collaborates with
businesses like SmartPac and CartonWrap to automatically package and package
items for shipping. Amazon.com launched the Upskilling 2025 program, which
includes a variety of initiatives to assist people in gaining skills and knowledge in
areas including software engineering, IT, machine learning, and cloud computing.
RoboMaker, a tool that enables developers to quickly construct and deploy robotic
applications, was accomplished by investments in cloud computing and storage. The
corporation has funded a new Tech Hub devoted to robotics research as part of its
ongoing investment in automation. With its latest research and patents on
autonomous delivery vehicles, Amazon is also aiming to expand into the delivery
sector. Amazon.com is an example of an ecommerce company that successfully
uses automation to create an efficient distribution network and growth.
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2.2.3 SOME OF THE KEY FEATURES OF AMAZON’S
SMART WAREHOUSES
• Automated storage and retrieval systems: These systems use robotics to

automatically store and retrieve goods from designated locations within the
warehouse, freeing up human workers to focus on other tasks.
• Intelligent conveyor belts: Amazon’s smart warehouses use advanced conveyor
belts that are equipped with sensors and machine learning algorithms to sort and
route packages to their destination.
• Picking robots: These robots use machine learning algorithms and advanced
sensors to identify and pick items from shelves and place them in the correct bins
for packing and shipping.
• Mobile robots: These autonomous robots move around the warehouse floor,
transporting goods and materials to the appropriate locations.
Overall, Amazon’s smart warehouses are designed to be highly efficient and
automated environments that use advanced technologies to optimize various
processes within the warehouse. These technologies help to improve the speed and
accuracy of order fulfillment, as well as increase productivity and reduce the need
for manual labor. Amazon’s smart warehouse is what makes their lightning-fast
delivery possible. Amazon continues to innovate every day with a heavy focus on
automating their supply chain.
2.3 SMART WAREHOUSE WORKFLOW AND

ARCHITECTURE
Every warehouse needs to define where and how products are moved. A well-
designed warehouse management process flow saves your business time and money.
It defines all the stages in your warehouse operations, so you can focus on getting
work done.
2.3.1 WORKFLOW
• INCOMING DOCKS
The inventory management operation is often started at this moment when the
warehouse's inflow begins at the arriving dock. When items arrive at this location,
they are checked in manually or, in the case of a smart warehouse, using barcodes,
RFID tags, or other distinctive IDs When items arrive at this location, they are
checked in manually or, in the case of a smart warehouse, using barcodes, RFID
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tags, or other distinctive IDs. It is simpler to track objects, goods, or products later
on during production, packing, or delivery when they all have unique IDs.
Figure 2-13 Unloading docks
• STORAGE AND RETRIEVAL
Simply putting the boxes on racks or shelves counts as storing the items in a typical
warehouse. No specific pattern or sequence has been created for that purpose, which
might reduce efficiency and make it challenging to trace the cartons if they are not
labelled. On the other hand, a smart warehouse uses a number of algorithms to store
the products. To keep the system running smoothly, every action from receiving the
items to placing them on the shelves—is carried out in accordance with a pre-
established set of instructions. Manually or, in the case of a smart warehouse, with
the help of Automated Guided Vehicles (AGVs), conveyer belts, or line-follower
robots, the products are moved to shelves or pallets. Any product may be obtained
through the same functionality whenever it has to be exported.
• The unloading process: Truck deliver pallets to an available unloading dock.

Pallets are then unloaded from the truck using a forklift and pallets are placed in the
receiving dock area. Additional forklifts then transport the pallets to the main
storage racks as shown in figure 2-13.
• The order assembly process: The order is assembled from pallets which can be
of the same or of different types. An order can be assembled if the required pallets
can be put in the assembly area near the docks (or if there is not enough space there -
in the additional storage zone), and the main storage has the required number of
pallets of required types. The order is assembled by forklift trucks as shown in figure
2-14.
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• The loading process: Once the orders are completely assembled, the orders are
assigned the loading dock, where they were assembled. Truck is then assigned to a
loading dock for receipt of orders. A forklift will fill the orders in the trucks from the
assembly area. The total amount of orders for one truck must take up at least half of
its capacity.
Figure 2-14 Robot holding the items to the unloading docks
• TRACKING AND COMMUNICATIONS
For efficient communication across departments, a warehouse's departments and

sections must be integrated overall. Traditionally, communication has been
maintained through the use of manual pen and paper techniques, such as creating
sales orders, demand orders, etc., and physically or electronically forwarding them to
other departments. IoT communication protocols are used in smart warehouses to
connect each department and item to one another. This guarantees effective
communication throughout the warehouse and prompt transmission and reception of
information. thousands of CPS components, such as different sensors, RFID readers
and tags, BLE beacons, and Wi-Fi APs, may be present. A dense local area network
made out of CPS devices exists (LAN). Some data in the LAN must be acquired on
time, including the data needed to identify human activity. The restricted wireless
transmission capacity, however, could make it impossible to collect real-time data
from such a huge number of CPS devices. Investigating time-effective
communication scheduling strategies is crucial as a result. The communication
scheduling system should also be energy-efficient for environmental reasons as
Figure 2-15 Relationship between publishers and subscribers
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• OUTGOING DOCK
The items that need to leave the warehouse are brought here; all the information from
the sales order is cross-checked, and the product or bundles of products are removed
from the inventory while the inventory records are updated. The check-outs can be done
manually or partially automatically but using scanners and RFID tags that are connected
with the software system can enhance efficiency and smooth up the flow. RFID is
considered a choice for positioning, identifying, information interaction, and warehouse
management in the smart warehouse as shown in figure 2-16.
Figure 2-16 An overview of how a smart warehouse works
• INFORMATON INTERCONNECTION AND

COMMUNICATION
Designing intelligent warehouses at the highest-level need’s information linkage.
In recent years, CPS and IOT which developed as the expansion of computer
networks into every device and object have emerged as essential collaborators in
allowing the integration of logistical activities. The ideal idea of connecting and
communicating logistical components, such as commodities, facilities, and elements,
becomes a reality with the assistance of CPS and IOT.
The connectivity between various processes and entities is improved in today's

warehouse practice by developing technologies such as RFID, warehouse
management systems (WMS), augmented reality (AR), reinforced learning, and
others. The evolution of warehouses may be influenced by interconnection
technology, which offers options to create information sharing and data collecting in
warehouses. Technology from the Internet of Things and the CPS, such as radio
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frequency, pick to light, and pick by voice, are frequently employed in the
warehouse picking process.
RFID is viewed as one option among connectivity technologies for the smart
warehouse's placement, identification, information interaction, and warehouse
management. Its advantages include low cost, great flexibility, configurability, high
efficiency, and non-contact sensing capability as shown in figure 2-17.
Figure 2-17 RFID warehouse system
Warehouse management are the primary uses of RFID in smart warehouses. The
RFID system's primary purpose, information sharing, has a big influence on how
well the warehouses communicate. For managing warehouse information
processing, work scheduling, and resource assignment, information accuracy is
important. Mathematical programming may be used to optimize the design of
warehouse layouts and storage allocation for strategic and tactical decisions.
Sensitivity analysis may be used to evaluate and provide conclusions about how
various strategic and tactical choices would affect the model's purpose. Applying a
few professional algorithms will allow you to solve the mathematical programming
model.
The simulation of warehouse systems is another option. To adapt to different

warehouse systems, simulation models are able to accurately simulate the system
reality and operating mechanism. The suggested techniques, algorithms, or
techniques are frequently compared and shown using simulation models.
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2.3.2 RFID TECHNOLOGY
Radio-Frequency Identification (RFID) was invented by Charles Walton as the first

patent holder for RFID technology. RFID uses electromagnetic fields radio waves to
automatically identify and capture information stored on a RFID card/tag attached
objects. where the RFID tag contains electronically stored information as shown in
figures 2-18 and 2-19.
Figure 2-18 RFID reader Figure 2-19 RFID tag
Therefore, even though barcodes have been widely used for a while, attention is
quickly turning to RFID-based solutions since they have several benefits over
traditional barcode-based solutions as shown in figure 2-20.
Figure 2-20 Difference between RFID and barcode
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2.3.2.1 TYPES OF RFID TAGS AND READERS AVAILABLE
• Types of Tags:
a) Basic passive RFID Tags: Useful for liquids, non-metals, and paper. The price is about $15.
b) Metal passive RFID Tags: Bigger passive tags that may be used on metal equipment or servers
in data centers. Approximately from $1.50 to $4.50 apiece.
c) Active RFID Tags: Active RFID tags can transmit a signal once every 30 seconds. With a read
rate of about 100%, it is automatic and extremely accurate.
• Types of Readers:
a) Handheld: passive RFID reader for manual auditing of a location, data centre rack, etc. is the b-
Reader. You may spend between $2500 and $3500 each person.
b) Fixed Position Passive: RFID Readers are installed in a Doorway to Detect Moving Assets. This
type of RFID reader can read RFID tags in fixed positions. Each gateway is expected to cost between
$15,000 and $25,000.
c) Active RFID readers: There are more than 2000 square feet of zonal coverage for active RFID
readers. Each item is priced between $1,250 and $1,500.
d) Active RFID Rack/Room Locators: Active RFID readers are necessary for RFID-based
room locators or rack locators to provide accurate rack or room locations. Consider $155-205 per person.
Figure 2-21 RFID system's process
Use passive RFID technology and portable devices if real-time data is not required and
labor is inexpensive. Spend money on active RFID if you need real-time data and
manpower is pricey. As a result, the way assets are received, distributed, and used varies
for each organization. Naturally, there is also the matter of fixed assets as shown in
figure 2-21.
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2.3.2.2 RFID TECHNOLOGY WORKING PRINCIPLES
• Communication protocol and the technology stack:
RFID is one of the fastest ways to improve transportation and logistics systems because
to its flexibility, reliability, and ability to read from a wide range of angles and through
different materials.
RFID offers communication protocols that make it possible for tags and readers to
cooperate:
1. TTF Protocol
• Tag the communication as soon as the reader field is detected. This will simplify
the tag logic but make it less secure because the tag doesn't care who it is interacting
with as long as there is a compatibility problem and enough field strength.
2. ITF Protocol
• Before sending information, tags wait for reader inquiry.
• It is recommended for our complex inventory management system because of its

outstanding security.
3. Computing Stack
• Programming reader interaction system: SQL, Java, and phpMyAdmin
• Developing a suitable database structure to enable the determination of all

necessary data, including history, times, present tags, previous tags, etc
• Middleware-Architecture and the database:
The SQL Server database serves as the back end for the Asset Tracking and Inventory
Management (ATIM) system. The enterprise's Intranet server, a virtual wide area
network (WAN), or an IP-based web interface can all be used to access the ATIM.
On their computer, tablet, or smartphone, an investor operator can use a web browser
(such as Chrome, Firefox, etc.) to interact with the interface.
The online application may also be compressed to produce an iOS and Android app.
Additionally, it updates each component's movement history in the ATIM database,
20
notifying staff via their cellphones. A middleware implementation is needed to combine
RFID data with the ATIM solution as shown in figure 2-22.
Figure 2-22 Middleware architecture
• The Asset Tracking and Inventory Management (ATIM) solution
Each tag in an ATIM system based on RFID is approved using a desktop reader.
The authority advises the solution that this tag must be monitored at every level because
it is now a part of the inventory. The package that will be monitored is then given the
tag. Crates are used to pack the shipments. Before being picked up by AGV and put into
a warehouse, the integrated scanner scans the shipments.
The entire warehouse is searched for tags by a person holding or AGV with an RFID
reader. When an RFID tag is missing, the warehouse management system alerts the
ATIM quality operator, who then investigates the situation. The containers will be
forked out once again and placed into a truck for shipment if the inventory does not
reveal any missing packages as shown in figure 2-23.
Figure 2-23 Architecture of RFID tags
21
No package enters the vehicle without first being monitored by an RFID reader, which
is installed at the unloading sites. The information is verified the tags that the desktop
reader has approved as shown in figure 2-24.
Figure 2-24 RFID retail 3.0
2.3.3 AUTOMATED STORAGE AND RETRIVAL SYSTEM
It's general belief that warehousing requires a lot of labor. Managing the manual
warehouse in the usual way has grown to be a challenging challenge for performance
improvement. Many warehouses now have automated equipment, which solves this
challenge. Automation is a technology that enables activities to be completed with little
physical work. It transforms warehouse operations in numerous ways, such as through
improved productivity, quick response to client requests, and a large decrease in labor
expenses and mistakes. Warehouse operations now frequently employ automated parts-
to-picker order picking systems.
Finding the best methods for the design and control of automated warehouse systems is
becoming increasingly difficult as computerized decision support technology develops
and spreads due to the huge increase in the use of automation facilities as shown in
figure 2-25.
Figure 2-25 Typical AS/RS
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It is necessary to analyze the internal connections between strategic and tactical
decisions as well as some system features when applying automation technologies to
warehouse design and operation. The numerous automated equipment featured in smart
warehouses will be covered in this part, along with certain system features that may be
used as significant considerations for making strategic and tactical decisions.
For automatic material handling with great speed and precision, warehouses frequently
employ the AS/RS warehousing system. It is a synthesis of automated machinery and
essential control activities. Even though AS/RS has been widely used for many years,
study on its operational choices is still quite valuable and may serve as a foundation for
other warehouse technologies in smart warehouses. Vehicle Storage and Retrieval
Systems AVS/RS, SBS/RS, compact AS/RS, and puzzle-based storage and retrieval
system are only a few of the numerous AS/RS versions that have been developed into
effective systems today. Numerous variables, including the arrangement of the rack,
aisle, cross-aisle, space, tier, form, depot, shuttles, and pick position, might have an
impact on the system setup of AS/RS and its variations.
Automated storage and retrieval systems, sometimes calledASRS or AS/RS, are a class
of computer-controlled devices that rapidly, precisely, and automatically deposit and
recover loads from specified storage locations in a facility
Figure 2-26 AS/RS
An Automated Storage and Retrieval System (AS/RS) is a set of tools and controls that
operate together to handle, store, and retrieve products more efficiently, accurately, and
accurately as needed as shown in figure 2-26.
Smaller automated systems to bigger computer-controlled storage/retrieval systems that

are fully integrated into a production and/or distribution process are examples of
systems.
2.3.3.1 CALSSIFICATIONS OF AS/RS SYSTEMS
• Unit-load AS/RS: Equipment for storing heavy loads (generally 1,000

pounds or more), commonly on pallets with a 100-foot or taller storage rack structure.
23
AS/RS is a general term for several computer-controlled techniques for automatically
depositing and recovering loads to and from specified storage location as shown in
figure 2-27.
Figure 2-27 Unit-load AS/RS
• Mini-load AS/RS: Like a unit-load AS/RS, a mini-load AS/RS handles lesser

weights, often weighing under 1,000 pounds as shown in figure 2-28.
Figure 2-28 Mini load AS/RS
• Vertical lift Modules (VLMs): With an automated inserter/extractor in the

middle that saves and retrieves the necessary trays, VLMs have a column of trays in the
front and rear of the module as shown in figure 2-29.
Figure 2-29 Vertical lift modules
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• Shuttles: Shuttles are used in either manufacturing or warehousing to automate
the handling of totes, trays, cartons, or all three in the same system as shown in figure 2-
30.
Figure 2-30 Shuttles
• Horizontal carousel: Horizontal carousels are made of a number of bins that

revolve horizontally along a track and are perfect for storing tiny bits and pieces as
Figure 2-31 Horizontal carousel
• Cube-based storage: Ultra-high-density goods-to-person piece picking

system which utilizes robots to store and retrieve inventory bins from a cubical storage
grid as shown in figure 2-32.
Figure 2-32 Cube based storage
25
• Vertical carousels: Which rotate vertically like a Ferris wheel, include a
number of shelves or carriers to offer high-density storage as shown in figure 2-33.
Figure 2-33 Vertical carousels
• Automated storage and retrieval Systems:
• Order picking: Retrieving and presenting required inventory to pickers
• Storage: Providing dense long-term buffering for small or large items that are
slow- to medium-movers
• Kitting: Providing an area to group component parts for assembly
• Consolidation: Providing a dynamic area to hold parts and items until all pieces
of an order can be merged ready for shipment. Often used for consumer, B2B and store
orders.
• Assembly: Storing work piece components for later production
• Production: Storing tooling and component parts for manufacturing processes
• Replenishment: Storing excess inventory for restocking of ancillary picking

systems.
• Applications of Automated storage and retrieval systems:
1-Enhances throughput potential
2-Raises accuracy levels to 99.99% and higher
3-Improves ergonomics by bringing goods to the user at a comfortable height, cutting

down on time spent walking, looking for things, lifting things, bending, and twisting.
26
4-Offers the maximum storage density available
5-Reduces the amount of wasted floor space (up to 85%+)
6-Raises worker productivity by 85% enhancing product security seven
8-Offers real-time inventory management
• Automated storage and retrieval systems used in:
1- Automotive
2- Beverage
3- Electronics
4- E-commerce
5- Food
6- Hospital
7- Manufacturing
8- Medical devices and equipment
9- Maintenance & repair operations (MRO)
10- Paper
11- Pharmaceutical
12- Plastics
13- Spare parts handling
14- Warehousing and distribution.
2.3.3.2 CLASSIFICATIONS OF AGVS AUTOMATED

GUIDED VEHICLE:
AGVs are automated guided vehicles used for moving horizontal materials. Order
picking with AGV assistance may accommodate both order picking of both small and
large products. AMR and robotized warehouse systems, which are based on AGV
technology, are being developed to supplement or replace human labor in product
picking and handling. In warehouses, AGV-based and robotized warehousing systems
27
are being used more and more. To save transportation times and distances for human
pickers, warehouse robots in the picker-to-parts mode may undertake collaborative
picking. The research of Lee and Murray (2019) mentions two different sorts of
warehouse robots. A certain kind of warehouse robot can pick goods up off the shelf,
while another kind can transport products from the picker to the workstation. The
chosen objects can also be sorted by robots.
Why AGVs Are Required in Smart Warehouse?
AGVs are effective in all warehouses, whether on a large or much smaller scale. They
support keeping your competitive edge and quick problem-solving. They are a one-time
investment that allows your staff more freedom in terms of the actions they can do and
the contracts they may sign.
You will no longer have to deal with conveyor belts that are static and partly cemented
into space. AGVs give your warehouse an open design that you can take advantage of.
Automated Guided Vehicles are programmed to return to their charging station when
necessary, usually scheduled during downtime in operations. Their road, the highway
they use during hours of operation, is cleared whenever you need it as shown in figure
2-34.
Figure 2-34 Different types of AGV
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2.3.4 TYPES OF AUTOMATED GUIDED VEHICLES
• Automated Guided Cart:
The most basic sort of AGV, having the fewest functions, is an automated guided cart
(AGC). Simple magnetic tape navigation systems to sophisticated sensor-based
navigation systems that employ artificial intelligence to navigate their surroundings are
all examples of navigation systems. They are frequently used in sorting, storage, and
cross-docking applications and can move a range of goods, including tiny components
and full pallets. An automated hospital cart transporter is one type of AGC that is used
to deliver small loads effectively across a hospital, including meals and empty food
trays, clean or used linens, biohazard trash, or sterile supplies. Automated hospital cart
transporters can aid in lowering expenses since they eliminate the need for a staff
member to physically push the cart from one location to another as shown in figure 2-
35.
Figure 2-35 Automated guided

cart
• Forklift AGVs:
Another frequently utilized kind of AGVs are forklift automated guided vehicles
(forklift AGVs). They are made to transfer pallets and carry out the same tasks that a
forklift driven by a person does, but without the requirement for a human operator as
Figure 2-36 Forklift AGV
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• Towing AGVs:
One or more non-powered, load-carrying vehicles are pulled behind towing vehicles or
tugger automated guided vehicles in a train-like arrangement. Powered towing vehicles
are on wheels and are sometimes referred to as autonomous trains. Heavy cargoes that
must be transported over longer distances are frequently transported using tugger
automated guided vehicles. Along a predetermined route through a warehouse or
factory, they could have multiple drop-off and pick-up stations as shown in figure 2-37.
Figure 2-37 Towing AGV
• Unit Load AGVs:
Individual objects or a single unit, such as a pallet or box containing several goods, are
carried by unit load handlers as shown in figure 2-38.
Figure 2-38 Unit load AGV
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• Heavy Burden AGVs:
Heavy weight carriers are a type of AGV utilized in applications including massive
assembly, casting, and coil and plate delivery for the largest loads. Some large freight
carriers may self-load and may feature omnidirectional, pivotal, or normal steering as
Figure 2-39 Heavy burden AGV
• Autonomous mobile robot:
The technology of autonomous mobile robots (AMRs) is often more sophisticated than
those of other AGV kinds. Many AMRs are equipped with intelligent navigation
features like sensors and camera systems that enable them to identify and navigate
around obstacles, in contrast to many AGVs that employ fixed navigation systems like
cables or magnetic tape. AMRs can dynamically roam a warehouse or other facility and
plan the most effective pathways thanks to more advanced technologies as shown in
figure 2-40.
Figure 2-40 Autonomous mobile robot
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2.3.4.1 AGVS WORKING PRINCIPLE
AGVs are self-propelled vehicles with movement guided by software and sensors. Most
AGVs move along defined pathways, but as mentioned, AMRs typically have more
advanced technology with dynamic navigation capabilities.
One or more of the following mechanisms may be used to direct AGV

navigation:
• Magnetic guide tape: Some AGVs include magnetic sensors and use magnetic
tape to follow a track. Some AGVs use wired navigation, following pathways that are
located in the facility floor. AGVs use an antenna or sensor to detect the signal that the
wire sends as shown in figure 2-41.
Figure 2-41 Magnetic guide tape navigation
• Laser target navigation: In this technique, reflective tape is attached to poles,

walls, and other stationary objects. A laser receiver and transmitter are included with
AGVs. In order to determine the object's angle and distance from the AGV, the lasers
reflect off the tape inside the line of sight as shown in figure 2-42.
Figure 2-42 Laser target navigation
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• Inertial (gyroscopic) navigation: To ensure that an AGV is on the right track,
certain AGVs are controlled by computer systems using transponders that are planted in
the facility floor. The mobile robot uses the pulse signal from the encoder to do basic
live calculation as it is moving to identify its position. The mobile robot's three-axis
angular velocity and acceleration may be measured using a gyroscope, and its position
can be determined using an integral operation and a combination of the two dead
reckoning techniques. Inertial navigation is inexpensive and provides excellent
positioning accuracy quickly, but the inaccuracy will increase with motion until it is
lost. Inertial navigation will thus often be utilized as a secondary positioning system for
other navigation techniques as shown in figure 2-43.
Figure 2-43 Inertial (gyroscopic) navigation
• Vision guidance: The infrastructure does not need to be changed for vision
guided AGVs. AGVs rely on the features that cameras have captured along the path in
order to navigate. In this method, the mobile robot captures the ground texture while
moving to automatically create the map, then compares the information it collected
about the ground texture while moving with the texture picture in the self-built map to
estimate the mobile robot's present location. Realize the mobile robot's placement by
positioning it as shown in figure 2-44.
Figure 2-44 Vision guidance
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• LiDAR (Light Detection and Ranging): LiDAR (Light Detection and
Ranging) uses sensors that send laser pulses to determine how far an item is from a
robot in order to navigate. Robots can travel the facility and avoid obstacles without the
need for extra infrastructure thanks to the 360-degree map of the environment that is
made using the data gathered from the various sources. In order to travel a warehouse
without requiring infrastructure improvements and to adapt to new settings should a
warehouse floor's layout change, 6 River Systems employs LiDAR navigation
technology as shown in figure 2-45.
Figure 2-45 Light detection and ranging
• Natural navigation: The natural navigation, which is a form of laser navigation,

is present here. Using the laser sensor, it can also detect its immediate surroundings.
The positioning mark of the laser navigation (reflector) is a reflector or a reflecting
column, whereas the marker may be found via natural navigation. Walls in the
workplace can provide information without the use of reflectors. Natural navigation has
a cheaper construction cost and cycle than conventional laser navigation. Natural
navigation may use contour data from features like walls to determine its location,
thereby reducing the need for the reflector and lowering building costs. Natural
navigation has the drawback of having a disproportionately high dependency on the
environment's contour as shown in figure 2-46.
Figure 2-46 Natural navigation
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• QR code guide: According to the two-dimensional code navigation theory, an
autonomous guided vehicle scans a QR code on the ground using a camera, and then
uses the two-dimensional code information to determine its present location. For
accurate placement, two-dimensional code navigation and inertial navigation are
frequently coupled. Now, two-dimensional code navigation is quite popular. The
primary explanation is that Amazon paid a significant sum to purchase the KIVA QR
code navigation robot. Its chessboard-like operation mode is amazing. Robots that read
QR codes are used in intelligent warehousing and domestic e-commerce as shown in
figure 2-47.
Figure 2-47 QR code guide
2.3.4.2 AGV STEERING
Differential speed control, steering wheel control, or a mix of the two are used to man
oeuvre AGVs:
The form of steering control utilized by AGVs most frequently is
• Differential speed control: Two separate driving wheels are used for
differential speed control. To turn, each driving wheel is propelled at a distinct speed.
The two drives are moved at the same pace whether moving forward or backward.
Differential speed control, the most straightforward steering option for AGVs, doesn't
need for extra steering motors or systems. It is frequently applied to AGVs that work in
constrained places or near other equipment. As a trailer may jackknife when turning, it
is not useful for towing activities.
• Steered wheel control: This sort of steering control is comparable to an

automobile or truck's steering wheel. The drive wheel serves as the turning wheel in
steering wheel control. The steering wheel control provides smoother turning and is
35
more accurate than differential speed control. It may also be operated by the operator
and is frequently utilized for towing operations.
• Combination steering: combines steering wheel control with differential speed

control. Combination steering AGVs have swiveling castors on the other two corners
and two separate steer/drive motors on the diagonal corners. Combination steering
allows AGVs to travel in any direction while turning in any direction.
2.3.4.3 AGV TRAFFIC CONTROL
Traffic control measures include zone control, collision avoidance or a mix of both:
• Zone control: Zone control is a popular traffic control technique for AGVs
since it is easy to establish and extend. An AGV has a sensor that receives the signal
and delivers it back to the transmitter once it is received in a specific region by a
wireless transmitter. A "clear" signal is delivered to allow the AGV to enter or pass
through the region if it is clear. A "stop" signal that warns other AGVs attempting to
enter that the region is not clear is sent if another AGV is in the nearby. The waiting
AGVs will stop and wait in this scenario until the first AGV leaves the zone and the
transmitter sends a "clear" signal.
• Collision avoidance: Avoiding collisions: AGVs that use collision avoidance

zone control are fitted with sensors that send out a signal and then wait for a response to
assess whether or not something is in front of them. These sensors might be optical,
which employs infrared sensors, or sonic, which functions like radar. Both operate in a
comparable way. Another kind of collision avoidance sensor is a bumper sensor. As a
fail-safe, bumper sensors are a common feature of AGVs. When bumper sensors detect
physical touch, they stop to prevent a crash.
• Combination control: To provide more reliable collision prevention in all

circumstances, AGVs that employ combination control are fitted with both zone control
sensors and collision control sensors. For instance, an AGV may employ collision
avoidance sensors as a backup in case the zone control system fails while still using
zone control as its primary traffic management system.
2.3.4.4 AGV SAFETY AND COMPLIANCE STANDARDS
• The Material Handling Industry of America (MHIA), which has created

standards and recommendations surrounding the deployment and usage of Automatic
Guided Vehicle Systems, suggested the standards that have been authorized by the
American National Standards Institute (ANSI). The MHIA standards provide safety
criteria for system makers, suppliers, and users as well as for the building, use, and
maintenance of systems.
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• The safety requirements for driverless, automatic guided industrial vehicles, and
other automatic industrial vehicles were established by the Material Handling Industry
of America (MHIA) in 2012.
• The requirements for emergency controls and bumpers are also covered in detail
in the specifications for AGV equipment. A manufacturer must be approved by the
MHIA in several categories before they can sell an AGV vehicle. AGVs and other
industrial equipment fall within the first category's general criteria.
• The remaining categories are primarily focused on AGVs and contain sections
on the types of authorized batteries, chargers, motors, and other electrical components
as well as the permitted wireless components.
It is advisable to check manufacturers' compliance with the MHIA requirements before

choosing to buy an AGV system. It functions as a sort of safeguard against poor
investments in various ways.
2.3.4.5 ADVANTAGES OF AGVS
Automated guided vehicles are specially made to do jobs that don't require people. They
control the pace for workers, automate long warehouse walks, and take the physical
difficulties out of a typically physically taxing profession. Chuck by 6 River Systems is
a flexible, scalable, and affordable option for distribution centers and warehouses that
offers cutting-edge technology created to address some of warehousing's most difficult
problems. AGVs offer numerous benefits in warehousing and manufacturing:
• Increase efficiency and productivity: AGVs are more productive and efficient
since they run on their own, and they are predictable and dependable for routine
activities. AGVs decrease wasted walking and the physical work associated with
moving things. They also set the pace for employees, ensuring that personnel stay on
target. Collaborative mobile robots and AGVs that coach employees through each
activity help to decrease human error, enhance order picking accuracy, and reduce
product waste. Collaborative mobile robots increase resource efficiency by using AI to
optimise routes and prioritise activities.
• Consistent costs: AGVs are frequently purchased on a per-unit or per-rental-

period basis, which results in less cost variation than human labour, which might change
depending on the state of the market and demand.
• Flexibility: some AGVs offer the flexibility of easily changing routes

(compared to others which require re-routing guide wires or other infrastructure to
adjust a vehicle’s route). Automated guided vehicles are a scalable solution, as well,
with the ability to add additional units based on demand.
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• Less space required: AGVs take up less area than other automation options like
conveyor systems. Some AGVs are smaller than forklifts and other typical warehouse
equipment, enabling floor plans with more efficient use of available space.
• Improved safety: And last, AGVs are a secure automation option for factories,
warehouses. AGVs include sensors to help them avoid collisions. The most effective
route across a warehouse or facility may be planned by advanced AGVs like AMRs,
which minimizes aisle congestion and reduces the risk of accidents.
From previous literature review of amazon smart warehouses which sums up the
objectives of the project, amazon is the top in this field, as amazon has the highest
technologies. The main objectives of the project is to implement software by anylogic to
optimize appropriate hardware which is the arrangement of the racks in the warehouse,
selecting the best AGV to achieve the warehouse demands, using RFID technology
which serving the warehouse with a lot of data and information, highest response of the
system, IOT monitoring and controlling warehouse, using collision sensor and zone
sensors to avoid AGVs collision inside the warehouse. All of these components are
integrated under a controlled software which manage all smart warehouse process and
simulations provide many scenarios inside the warehouse and choosing the best
efficient scenario.
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Chapter Three
3 METHODOLOGY
3.1 INTRODUCTION
In this section the software that has been chosen to simulate the model, main
components of the model, flowcharts, and workflow and process of this model will be
presented.
The main components of the model are racks, transporters which are the AGVs in this
case, conveyor belts. Those components are controlled by a set of flowcharts which in
their properties one can choose the scenario which will be simulated in this model.
The scenario here begins when the conveyors start to move the items and the AGVs
start to move towards the conveyor to pick them up and store them in the chosen rack
cell. When the storage is full and has reached the full capacity the AGVs start to retrieve
them from the storage to a specified place which the truck will take them away.
3.2 ANYLOGIC SOFTWARE
AnyLogic is the leading simulation modeling software for business applications,

utilized worldwide by over 40% of Fortune 100 companies.
AnyLogic simulation models enable analysts, engineers, and managers to gain deeper
insights and optimize complex systems and processes across a wide range of industries.
AnyLogic includes a graphical modelling language and also allows the user to extend
simulation models with Java code. The Java nature of AnyLogic lends itself to custom
model extensions via Java coding. The Professional version allows for the creation of
Java runtime applications which can be distributed to users.
AnyLogic Cloud allows users to run models using web browsers, on desktop computers
and mobile devices, with the model being executed on the server side. Multiple run
experiments are performed using several nodes.
The results of all executed experiments are stored in the database and can be
immediately accessed.
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• Anylogic features
1. Convert flowcharts into interactive movies with spectacular 3D and 2D graphics.
2. Present your simulation models to stakeholders in a visually attractive and self-

explanatory way.
3. Use the extensive set of graphical objects to visualize vehicles, staff, equipment,
buildings, and other items and processes related to your business.
4. Import custom 3D models, images, CAD drawings, and shape files into your
simulations.
5. Make your simulation models interactive by adding intuitive navigation and

controls.
6. Turn your simulations into comprehensive management dashboards.
• AnyLogic provides a unique suite of industry-specific tools in

one package, at no additional cost:
1. Process Modeling Library for generic business processes or workflows.
2. Fluid Library to simulate bulk cargo and liquid transfer in industries like mining
or oil & gas.
3. Rail Library for rail transportation, terminals, and yards.
4. Pedestrian Library for pedestrian flows in airports, stadiums, stations, or

shopping malls.
5. Road Traffic Library for car, truck, and bus movement on roads, parking lots,
and factory sites.
6. Material Handling Library for manufacturing and warehouse processes.
AnyLogic can be used as warehouse simulation software, which flexible capabilities

give you the power to model a warehouse as in the real-world; the structure, the
processes, and the resources. Through simulation, and visualization, one can develop
the best warehouse design, layout and operations for today and the future. AnyLogic
features the Material Handling Library, a specially designed toolkit that simplifies the
simulation of warehousing operations. The library helps when designing detailed
models of storage facilities.
To learn more, get our Material Handling Pack of related videos, case studies, and how-
tos, or read our Material Handling Simulation white paper.Using warehouse simulation
software is key to the detailed analysis and optimal function of an organization.
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3.3 CONTROL
RC cars control is a pivotal aspect. The structure of an RC car encompasses several

essential components. The chassis acts as the main frame, constructed from lightweight
materials like aluminum, carbon fiber or acleric to ensure durability.
Wheels and tires, made of materials such as rubber or foam, provide traction for
movement. The motor, whether electric or gas-powered, propels the car forward. Power
is supplied by rechargeable batteries, which energize not only the motor but also other
electronic components like the sensors and actuators. Precise control over speed and
direction is achieved through the implementation of an H-bridge, an electronic circuit
consisting of switches that govern current flow to the motor.
The electronic speed controller (ESC) converts signals from the radio system into motor
instructions using pulse width modulation (PWM). Additionally, RC cars often
incorporate sensors such as the Husky Lens, an AI machine vision sensor with various
functions.
The TCRT5000 Infrared (IR) sensor, which utilizes IR signals for different purposes.
These components and control systems can be integrated with platforms like Arduino,
enhancing the capabilities and creativity in designing RC car projects. Together, these
elements contribute to lightweight, durable, and efficient structures, maximizing
performance and driving control as shown in figure 3-1.
Figure 3-1 RC car
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3.3.1 PROCESS FLOWCHART
• The truck arrives at unloading area, the boxes are checked automatically with
TAGs, and the inventory management operation is often started at this moment
when the warehouse's inflow begins at the arriving dock.
• Then controller request the AGV to move from parking to desired location in the
warehouse.
• The AGV starts moving with line tracking sensor towards to desired destination
which is the loading Dock and stops based on camera reading TAG.
• The AGV knows the desired destination as the camera detect the desired TAG of
the location and then comparing it with the desired tag.
• If “YES” controller confirmed the tag with desired destination and AGV ordered
to stop, if “NO” the AGV keeps moving with shortest path till the camera detect
the desired tag of the location.
• If the AGV stops at the desired storage unit to unload box as every action of
receiving the boxes to place them on the shelves is carried out in accordance with
a pre-established set of instructions of simulation.
• Then AGV returns to the parking area waiting for another order (unloading or
loading) provides by the controller and simulation scenario.
• Then if the AGV received an order it starts moving to the storage units to load the
boxes to the desired destination which is the loading area waiting for truck to
load the order.
• At the end it returns back to the parking waiting for an order (loading or
unloading) as sown in figure 3-2.
Figure 3-2 Process flowchart
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3.4 OBJECTIVES
• The project encompassed both the development of a simulation model using

AnyLogic software and the construction of a physical prototype for the smart
warehouse.
• The physical prototype involved the use of a remote-controlled car (RC car)
powered by an Arduino microcontroller.
• To navigate within the warehouse, the RC car relied on a line tracking sensor,
enabling it to follow predefined paths accurately. Additionally, a HuskyLens
camera was incorporated into the system to scan QR codes strategically placed
throughout the warehouse.
• These QR codes provided crucial information about item locations and
destinations. By integrating the simulation model with the physical prototype,
the project aimed to validate the feasibility and effectiveness of the smart
warehouse concept in a real-life setting.
• This combined approach allowed for a comprehensive evaluation of the system's
performance and provided insights into potential improvements and
optimizations for future implementation.
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Chapter Four
4 SIMULATION
4.1 INTRODUCTION
This model of a simple smart warehouse demonstrates how the logic of Transporter can
be used to put items on pallet racks and retrieve them later. In the model AGVs take
boxes from conveyor and deliver them to the rack cells that were reserved for them.
When storage capacity comes to its maximum, a group of boxes is retrieved and
delivered to the truck by AGV. This model was built with the Process Modeling Library
and Material Handling Library.
This model can be animated in 2D and 3D. In 2D the model is viewed from the top as
shown in the figure below. 3D animation is the most realistic and natural way of
visualizing the simulated process as shown in figures 4-1 and 4-2.
Figure 4-1 2D model Figure 4-2 3D model
4.2 ARCHITECTURE LAYOUT
The layout of this model consists of a network of paths and nodes, shown below, in
which the AGVs are used to navigate through the modelled warehouse to pick the items
from the conveyer belts and store them in the correct cell. This system not only does it
allow us to store items but also retrieve them as well from the storage system and takes
them to the loading dock where a truck will be waiting to pick up the items.
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This specific layout allows the AGVs to navigate inside the warehouse without colliding
with each other as well as reaching the desired places in the shortest time as shown in
figure 4-3.
Figure 4-3 Architecture layout
4.3 MAIN COMPONENTS OF THE SIMULATION
1. Conveyor Belt:
Conveyor belt is the space markup shape that graphically defines a conveyor. To
simulate how conveyors transport material items, use the AnyLogic Material Handling
Library Blocks Convey, Conveyor Enter, and Conveyor Exit as shown in figure 4-4.
A single conveyor automatically composes a conveyor network that one can extend by
connecting more conveyors together. In the conveyor network, material items always
move along the shortest route from the origin to the destination. Conveyor starts moving
with the defined initial speed and accelerates to the defined maximum speed. This
maximum speed is sustained until conveyor stops. Conveyors can serve as obstacles on
the way of pedestrians and transporters moving in free space navigation mode.
Figure 4-4 Conveyor belt
• Conveyor types
By default, the conveyors in AnyLogic are roller conveyors, but if necessary one can set
it to be of any available type:
a) Roller
b) Belt
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c) Fixed cell
In this simulation the Roller Type was used.
2. Transporters (Automated guided vehicle):
Transporters are vehicles used to transport material items in the modeled environment.
They are defined by TransporterFleet block of Material Handling Library.
Depending on the navigation type, the transporters movement is conducted either along
network paths and nodes or in free space. In this case the network paths and nodes are
being used as mentioned earlier in the layout section Additional rules for transporter
fleets with path-guided navigation type, such as custom routing, are specified in
TransporterControl block as shown in figure 4-5.
By default, transporters with the same navigation type recognize each other as obstacles,
but one can also make them recognize transporters with a different navigation type.
Figure 4-5 AGVs transporting items from conveyor belts
3. Pallet Rack:
The space markup element Pallet Rack graphically defines the pallet rack used in
warehouses and storage zones. Shown below is a picture of pallet rack as shown in
figure 4-6.
Figure 4-6 Pallet racks
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Pallet rack may have one of these three configurations:
One aisle, one pallet rack
Two aisles, one pallet rack
One aisle, two pallet racks
In this model the one aisle, one pallet rack was used.
4.4 ENITIES
Anylogic converts flowcharts into interactive movies with spectacular 3D and 2D

graphics. In this model some flowcharts have been used to simulate it that will be
discussed briefly as shown in figure 4-7
Figure 4-7 Anylogic flowchart
1. Source
Generates agents. Is usually a starting point of a process model. The agents may be
standard, or of any user-defined agent type. One can customize the generated agents by
specifying the agent type in new agent field, and then specifying the action that should
be performed before the agent exits the Source block in on exit action field as shown in
figure 4-8.
Figure 4-8 Source
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2. Convey
Transports the incoming agents (material items) to the specified destination point of a
conveyor network. The one and only block that controls material items movement
within a conveyor network as shown in figure 4-9.
Material item’s route can be specified explicitly as a sequence of conveyors or

calculated automatically. Automatically calculated route is the shortest sequence of
conveyors between the source and target points. One can customize this route by
including or avoiding specific conveyors in the route (Avoid conveyors and Include
conveyors options).
Figure 4-9 Convey
3. MoveByTransporter
It is the block that performs transportation of an agent by a transporter. One define a

fleet of transporters of a certain type using the TransporterFleet block. An example of a
transporter is an AGV (automated guided vehicle). Transporters move along network
paths. By default transporters take the shortest route. If needed, One can manage the
routing by yourself by providing the path selection algorithm in the corresponding
TransporterFleet block. The MoveByTransporter block provides a complete set of
parameters for seizing a transporter, loading it with the required agent, sending it to the
specified location, unloading the agent there, and finally releasing the transporter.
Seizing and releasing actions can be modeled by the corresponding SeizeTransporter

and ReleaseTransporter blocks (use them to design a more detailed agent transportation
flowchart). In this case, make sure to disable the Seize transporter and Release
transporter parameters of this MoveByTransporter block as shown in figure 4-10.
Figure 4-10 MoveByTransporter
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4. RackStore
RackStore puts agent into a cell of a given pallet rack, or RackSystem. The agent is
moved from its current location in the network to the cell location, optionally with the
help of moving resources as shown in figure 4-11.
Optionally, a delay may be associated with putting an agent into a cell; the delay may
depend on the cell coordinates, e.g. on its level.
Figure 4-11 Rack store
5. Queue
A queue (a buffer) of agents waiting to be accepted by the next block(s) in the process
flow, or a general-purpose storage for the agents. Optionally, you may associate a
maximum waiting time with an agent. You can also remove agents from your code from
any position in the queue as shown in figure 4-12.
The queuing discipline may be FIFO (which is used in this model), LIFO, or priority-
based. The priority may be explicitly stored in the agent or calculated based on the agent
properties and external conditions. A priority queue always accepts an incoming agent,
evaluates its priority and places it at the corresponding position in the queue.
Figure 4-12 Queue
6. Hold
Can block the agent flow along a particular connection. Is used, for example, when the
succeeding flowchart block can accept agents, but you (temporarily) do not want the
agents to proceed there, or when you wish to block an output of a particular flowchart
block that merges with outputs of other blocks as shown in figure 4-13.
Figure 4-13 Hold
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7. SeizeTransporter
Seizes one transporter from the specified fleet defined by the TransporterFleet block.
Sends the seized transporter to the specified location as shown in figure 4-14.
Figure 4-14 Seizetransporter
8. RackPick
RackPick removes agent from a cell in the specified pallet rack, or RackSystem and
moves it to the specified destination location. This is optionally done with the help of
moving resources, and, also optionally, a delay may be associated with picking the
agent as shown in figure 4-15.
Figure 4-15 Rack pick
9. Batch
Converts a number of agents into one agent (batch) by either discarding the original
agents and creating a new one — permanent batch (whose properties possibly depend
on the original ones), or by adding the original agents to the contents of the new agent
— temporary batch that can later on be unbatched by Unbatch block as shown in figure
4-16.
Figure 4-16 Batch
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10. TransporterFleet
Defines a fleet of transporters that can be seized and released by agents (material items)
using SeizeTransporter and ReleaseTransporter flowchart blocks of the Material
Handling Library as shown in figure 4-17.
Transporters have their home locations where they can optionally return. The
transporters in one fleet can have individual properties, can be animated, collect unit-
based statistics, etc. Depending on the selected type of navigation, transporters can
move either along network paths and nodes or in free space. By default transporters take
the most efficient route to the target.
Figure 4-17 Transporter fleet
11. RackSystem
RackSystem is used to represent a number of storages as a single block with multiple
rows and aisles and serves as a central access and management point for them. This
makes sense if the storages are used in a similar way as shown in figure 4-18.
Figure 4-18 Rack system
12. Function
AnyLogic enables defining your own functions. Function will return the value of an
expression each time the user calls it from the model. Functions are helpful when you
need to re-use the same function in multiple places in your model. Since you write
functions in Java, you have all the advantages of this language, such as conditional and
cyclic operators, branches, and more as shown in figure 4-19.
Figure 4-19 Function
13. 3D Window
3D window plays the role of a placeholder for 3D animation. It defines the area on the
presentation diagram where 3D animation will be shown at runtime. If you want 3D
animation to be displayed for your agent, you must add 3D window onto its diagram.
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4.5 WORKFLOW AND PROCESS
Firstly, items are placed on conveyors as they reach the end of the belt the AGVs start to
move towards them from their designated parking space and start of pick up the first
item to store it in an organized FIFO mode.
The FIFO mode events run in the following order: A, B, A, B, A, B, A, B, which will
store the first items that have been conveyed and transported by the AGVs and will
retrieve them with the same order.
AGVs move on the network of paths and nodes which were specifically designed to
avoid colliding with each other in order to save time, cost, and energy which are the
main goals of building a successful smart warehouse.
Movement is always performed along the shortest path between the origin and the
destination nodes, which are connected together to make up the network.
Once the maximum capacity of the storage system is reached a group of boxes is
retrieved and delivered to the truck by AGV.
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Chapter Five
5 LIST OF COMPONENTS AND DESIGN
5.1 LIST OF COMPONENTS
Prototype AGV modeling
Figure 5-1 AGV prototype
The structure of an RC car can vary depending on the type of car and its intended use,
but most RC cars will have some common components and features. Here are some of
the typical structural components of an RC car:
1) Chassis: The chassis is the main frame of the RC car that supports all the other
components. It is usually made of lightweight materials like aluminum or carbon
fiber and is designed to be strong and durable as shown in figure 5-2 and 5-3.
Figure 5-2 Chassis top view Figure 5-3 Detailed chassis top view
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2) Wheels and tires: The wheels and tires are what provide traction and allow
the car to move. The tires can be made of different materials depending on the
surface the car will be driving on, such as rubber or foam as shown in figure 5-4.
Figure 5-4 Tyre dimensions
3) Motor: The motor is what powers the car and drives the wheels. It can be an
electric motor or a gas-powered engine, depending on the type of car as shown
in figure 5-5 and figure 5-6.
Figure 5-5 DC motor
Figure 5-6 DC motor specifications
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4) Battery: The battery provides power to the motor and other electronic
components like the radio system and servos. RC car batteries are usually
rechargeable and can be made of different types, such as nickel-metal hydride
(NiMH) or lithium polymer (LiPo) as shown in figure 5-7.
Figure 5-7 Battery
5) H-Bridge: An H-bridge is an electronic circuit that is commonly used in RC

cars to control the speed and direction of the motor. It consists of four switches,
typically transistors, which are arranged in a configuration that resembles the
letter "H". The motor is connected to the center of the H-bridge, while the
switches control the direction and speed of the current flowing through the
motor. It allows for precise control of the motor and helps to ensure that the car
can move in different directions at different speeds as shown in figure 5-8.
Figure 5-8 H-Bridge
6) Electronic speed controller (ESC): The ESC is what controls the speed
and direction of the motor. It converts the signal from the radio system into a
signal that the motor can understand uses pulse width modulation (PWM) to
adjust the speed of the motor, by varying the amount of time that the switches in
the H-bridge are turned on and off.
Overall, the structure of an RC car is designed to be lightweight, durable, and

efficient, in order to provide maximum performance and control while driving.
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5.2 SENSORS
1) IR sensor: The TCRT5000 Infrared sensor mainly includes an IR Tx

(transmitter) & and IR Rx (receiver). Here transmitter and receivers are Photodiode
& a Phototransistor. Once the voltage supply is provided to the IR Tx unit then it
immediately transmits & emits IR signals. Once these signals crash through an
object, then the IR receiver gets the signals. Here the transmitter functions similar
to a transistor, apart from the base terminal are excited through light as shown in
figure 5-10.
Figure 5.9 TCRT5000
Sensor specifications:
• 3-way tracking sensors for maze solving and line tracking robot projects
• The use of infrared light detection, anti-interference ability
• The sensor uses TRT5000, high sensitivity, stable performance
• Operating voltage 5V, black line output low, output high white line
• 5V power supply
2) Husky Lens: Husky Lens is an easy-to-use AI machine vision sensor with 6

built-in functions: face recognition, object tracking, object recognition, line
following, color detection and tag detection. Through the UART / I2C port, Husky
Lens can connect to arduino, Raspberry Pi, or micro-bit to help you make very
creative projects without playing with complex algorithms as shown in figure 5-9.
Figure 5-10 Husky lens
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5.3 CONTROL AND CIRCUIT CONNECTIONS
• Connectors: 4 pin connector in UART mode as shown in figure 5-11.
Figure 5-11 Connection types
• Protocol type: Husky lens supports three UART baud rates (9600,
115200, 1000000), and I2C protocol. In addition, it supports auto-detection
of the protocols, that is to say, Husky lens will automatically switch
between UART and I2C. We recommend to use the auto detection protocol,
which is simple and convenient. The default value is auto-detection.
5.4 OPERATIONS
1) Line learning: Point the "+" symbol at the line, then point the yellow
frame at the background area. It is recommended that within the view field of
Husky Lens, just remain lines to learn and no any cross lines as shown in figure
5-12.
Figure 5-12 Line learning technique
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2) Line prediction: When Husky Lens detects the line which has been
learned, a blue arrow will appear automatically on the screen. The direction of
the arrow indicates the predicted direction of the line as shown in figure 5-13.
Figure 5-13 Line prediction technique
3) Tag Detection: You can use the following tag / QR code pictures to test
this function. Point the “+” symbol at the tag, and press the “learning button”.
A yellow frame with words "Tag:ID1" will be displayed on the screen,
indicating that Husky Lens is learning the tag as shown in figures 5-14, 5-15, 5-
16.
Figure 5-14 Different QR codes Figure 5-15 Tag identification
Figure 5-16 Tag detection
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4) Tag recognition: When encountering the learned tag, a blue frame with an
ID will be automatically displayed on the screen as shown in figure 5-17.
Figure 5-17 Tag recognition
5) Learning multiple tags: The default setting is to recognize a single tag,

so we need to enable “Learn Multiple” parameter of the tag recognition
function as shown in figure 5-18.
Figure 5-18 Step one of learning
Similarly, the ID is related to the order of learned tags as shown in figure 5-19.
Figure 5-19 Step two of learning
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5.5 DESIGN
The exterior design of the AGV contains 3 main parts.

Firstly the base of the AGV is made up of two acrylic panels held together with
metal braces and rods tied together with bolts to the acrylic, on the lower panels 4
DC motors are mounted at the position where each wheel will be located on the
upper panel is where all the control components are located such as the Arduino,
h-bridge and power supply as shown in figure 5-20 and 5-21.
Figure 5-20 Exterior AGV design Figure 5-21 AGV's top view and dimensions
Secondly the wheels, made from plastic with rubber tyres which are fitted to the motors
with a key like design to avoid slip as shown in figure 5-22.
Figure 5-22 Motor and tyre dimensions
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Lastly the cover that sits on top of the base to cover all the wiring and other components
the cover was designed on auto desk inventor to fit on the base to comply with the rest of
the design as shown in figure 5-23.
Figure 5-23 AGV's exterior cover
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Chapter Six
6 CONTROL AND CIRCUIT CONNECTIONS
CONTROL AND CIRCUIT CONNECTIONS
The circuit shown in figure 6-1 designed for controlling (HuskyLens,IR,and H-bridge),
through this table illustrates the power consumed and signal taken.
COMPONENTS POWER ARDUINO SIGNAL
Motors 3v/100mA DI:2-3-4-5

IR Sensor 5v DI:6-7-8
HuskyLens 3.3v TX-RX
H-Bridge 12v DI: VIN
Table 6-1 Specifications
Figure 6-1 AGV circuit
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Chapter Seven
7 CONCLUSION AND DISCUSSION
7.1 INTRODUCTION
In this final chapter, we will conclude our exploration of the traditional warehouse
problem and the proposed solution of the smart warehouse. Throughout this book,
we have examined the limitations and inefficiencies of traditional warehousing
practices and how emerging technologies can revolutionize the industry. In this
concluding chapter, we will summarize the key points discussed and evaluate the
potential impact of smart warehouses on the future of logistics and supply chain
management.
7.2 RECAPITULATION
To recapitulate, we began by outlining the challenges faced by traditional

warehouses, including inefficient inventory management, limited visibility, and
labor-intensive processes. We then introduced the concept of smart warehouses,
which leverage technologies such as Internet of Things (IoT), artificial intelligence
(AI), robotics, and automation to optimize operations and improve overall
efficiency.
7.3 ACHIVEMENTS AND ADVANTAGES
Throughout the book, there was some highlighted achievements and advantages
offered by smart warehouses. These include:
• Real-time visibility: Smart warehouses provide granular visibility into

inventory levels, location, and movement, enabling accurate demand
forecasting, efficient order fulfillment, and reduced stockouts.
• Enhanced efficiency: Automation and robotics streamline repetitive tasks,

reducing human error, improving picking accuracy, and accelerating order
processing.
• Optimal space utilization: Advanced algorithms and intelligent systems

optimize warehouse layout and storage space, maximizing capacity
utilization and reducing storage costs.
63
• Improved safety: Collaborative robots and AI-powered systems minimize
the risk of accidents, ensuring a safer working environment for warehouse
personnel.
• Cost savings: Smart warehouses offer cost-saving opportunities through

reduced labor costs, optimized inventory management, and efficient energy
consumption.
7.4 IMPACT ON SUPPLY CHAIN
The adoption of smart warehouses has the potential to revolutionize the entire
supply chain. By enabling seamless integration with suppliers, manufacturers,
distributors, and retailers, these intelligent systems facilitate end-to-end visibility
and collaboration. Real-time data sharing and predictive analytics drive proactive
decision-making, leading to improved demand forecasting, reduced lead times, and
optimized supply chain performance.
7.5 CHALLENGES AND CONSIDERATIONS
While the concept of smart warehouses holds immense promise, it is essential to

acknowledge the challenges and considerations associated with their
implementation. Some key areas to address include:
• Technology integration: Integrating various technologies and systems

within a smart warehouse ecosystem requires careful planning,
coordination, and investment.
• Workforce upskilling: The transition to smart warehouses necessitates

upskilling the workforce to adapt to new technologies and roles, ensuring
a smooth transition and maximizing the potential benefits.
• Security and privacy: With increased connectivity and data exchange,

smart warehouses must prioritize cyber security measures to protect
sensitive information and maintain customer trust.
• Scalability and adaptability: As technology continues to evolve, smart

warehouses must be designed with scalability and adaptability in mind to
accommodate future advancements and changing business requirements.
64
7.6 FUTURE OUTLOOK
Looking ahead, the future of warehousing holds tremendous opportunities for

innovation and optimization. Smart warehouses will continue to evolve,
incorporating advancements in AI, machine learning, autonomous vehicles, and
predictive analytics. Additionally, emerging technologies like block chain have the
potential to enhance transparency, traceability, and trust within the supply chain
ecosystem.
7.7 CONCLUSION
In conclusion, the traditional warehouse problem addressed in this book calls for a
paradigm shift in the way we approach warehousing and logistics. Smart
warehouses present a transformative solution, leveraging technology to optimize
operations, enhance efficiency, and revolutionize the supply chain. By embracing
the potential of smart warehouses, businesses can gain a competitive edge, drive
cost savings, and deliver superior customer experiences. It is imperative for
industry stakeholders to stay abreast of technological advancements and embrace
the opportunities presented by the smart warehouse revolution.
65
7.8 APPENDIX
66
7.9 REFRENCES
https://www.geekwire.com/2022/with-new-warehouse-robots-amazon-looks-to-invent-
its-way-out-of-its-safety-problems/
https://www.aiplusinfo.com/blog/inside-amazons-smart-warehouse/
https://www.supplychaintoday.com/inside-amazons-smart-warehouse/
https://6river.com/what-are-automated-guided-vehicles/
https://www.conveyco.com/technology/asrs/vertical-lift-module-vlm/
https://www.online-sciences.com/technology/automated-storage-and-retrieval-system-
asrs-or-asrs-advantages-and-disadvantages/
https://www.jracking.com/asrs-automated-storage-and-retrieval-system/automatic-
storage-and-retrieval-system-asrs.html
https://www.daifuku.com/solution/intralogistics/products/automated-
warehouse/unitload-asrs/
https://gieicom.com/en/products/automated-storage/unitload-asrs/
https://bluebotics.com/agv-navigation-methods-virtual-path-following/
https://spectrum.ieee.org/three-engineers-hundreds-of-robots-one-warehouse
https://aws.amazon.com/robomaker/
https://aws.amazon.com/
Lerher T (2018). Aisle changing shuttle carriers in autonomous vehicle storage and
retrieval systems. International Journal of Production Research, 56(11): 3859–3879
https://www.google.com/search?q=INFORMATON+INTERCONNECTION+in+smart
+warehouse&rlz=1C1GCEA_enEG1039EG1039&ei=Nn-
5Y_zIBuW8kdUPvJOT0AU&ved=0ahUKEwj8u92q07X8AhVlXqQEHbzJBFoQ4dUD
CA8&uact=5&oq=INFORMATON+INTERCONNECTION+in+smart+warehouse&gs
_lcp=Cgxnd3Mtd2l6LXNlcnAQAzIHCCEQoAEQCjoKCAAQRxDWBBCwAzoICCE
QFhAeEB06BAghEBVKBAhBGABKBQhAEgExSgQIRhgAUK4aWKw7YKtAaAJw
AXgAgAH3AogBoRmSAQgwLjE1LjEuMpgBAKABAcgBCMABAQ&sclient=gws-
wiz-serp
AGVs safety ANSI: preview_ANSI+ITSDF+B56.5-2012.pdf
67

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Arab Academy for Science, Technology and Maritime

College of Engineering and Technology

B. Sc. Final Year Project

Design and implementation of smart warehouse

Amr Sameh Khalaf

Asser Safwat hussien toktomosh

Ahmed Tarek Mohamed

Mostafa Mahmoud Mohamed

Mostafa Mohamed Mahmoud Hassan

Signed: Omar Mohamed Nour El Dien

Registration No.: 17104346

Signed: Amr Sameh Khalaf

Registration No.: 18105538

Signed: Asser Safwat Hussien Toktomosh

Registration No.: 18106392

Signed: Ahmed Tarek Mohamed

Registration No.: 18104393

Signed: Mostafa Mahmoud Mohamed

Registration No.: 18104780

Signed: Mostafa Mohamed Mahmoud Hassan

Registration No.: 18104959

Date: Wednesday, 11 January 2023.

A method of more efficient management that generates a variety of rewards is smart

LIST OF FIGURES ................................................................................................................................... III

LIST OF TABLES ......................................................................................................................................VI

LIST OF ACRONYMS/ABBREVIATIONS .......................................................................................... VII

LIST OF UTILIZED STANDARDS ..................................................................................................... VIII

LIST OF REALISTIC CONSTAINTS ...................................................................................................... X

2 LITERATURE REVIEW AND BACKGROUND .............................................................................. 3

2.1 Introduction ................................................................................................................. 3

3.1 Introduction ............................................................................................................... 39

4.1 INTRODUCTION ...................................................................................................... 44

5 LIST OF COMPONENTS AND DESIGN ......................................................................................... 53

5.1 LIST OF COMPONENTS ......................................................................................... 53

6 CONTROL AND CIRCUIT CONNECTIONS ................................................................................. 62

CONTROL AND CIRCUIT CONNECTIONS ..................................................................... 62

7 CONCLUSION AND DISCUSSION .................................................................................................. 63

7.1 INTRODUCTION ...................................................................................................... 63

Figure 1-1 Robots in a smart warehouse ........................................................................................1

Table 6-1 Specifications ..............................................................................................................62

IEEE 802.11 - Wireless LAN (Wi-Fi) standard

Distance from from loading to storage unit 930 mm

Distance from from storage unit to unloading 1950 mm

Technology is increasingly transforming the way the world looks as we

Figure 1-1 Robots in a smart warehouse

Figure 1-2 Overview layout for anylogic

Chapter Two will be showing the literature review and background

2 LITERATURE REVIEW AND BACKGROUND

Figure 2-1 Example of amazon's warehouses

In principle, a warehouse is an inventory that may be subdivided into numerous

Figure 2-2 A generic display of the departments in a warehouse

2.2 AMAZON WAREHOUSE:

Figure 2-3 The startup of amazon

There is a lot of technology that is working behind the scenes in Amazon

Figure 2-4 Kiva's robot design

CANVAS Technology, which was established in 2015, is to move items through a

Figure 2-5 Canva's cart

Amazon.com is continually attempting to advance technologies for grabbing things.

Figure 2-7 Soft robotics’ robot hand