This document discusses the integration of an automated storage and retrieval system (ASRS) at a steel plant to improve efficiency and reduce costs. It describes the key components of the ASRS including a 3 degree of freedom overhead crane with lifting capacity of 100 tons and maximum height of 22 meters. The system uses PLC controllers and sensors to automate the storage and retrieval cycles by moving items to and from specified rack locations. A HMI screen allows operators to input commands and view system status including pallet availability and crane position. The ASRS is aimed to increase storage density, throughput, and reduce labor costs compared to a manual system.

2. Integration via OPC UA Server and Edge Gateway* (Data visualization –Lack of operation insight)
Firewall
Container
Registry
OPC
publisher
module edgeHub
edgeAgent
…
OPC UA
custom
module
Azure Data
Explorer
• Scalable telemetry DATA
Layer B
OPC UA
or
2
4 5
IoT Hub
or
Azure
IoT Central
OPC
publisher
module edgeHub
edgeAgent
…
OPC UA
custom
module
2 OPC
publisher
module edgeHub
edgeAgent
…
OPC UA
custom
module
3
6
7
8
Layer 0~2
OPC
publisher
module edgeHub
edgeAgent
…
OPC UA
custom
module
OPC
publisher
module edgeHub
edgeAgent
…
OPC UA
custom
module
1 2
Azure data factory
(ADLS Gen 2)
(Extract, Transform
& Load process)
Azure SQL
database
Analog to digital
converter
Local computer
Sensor PLC Layer B Layer C Visualization
Layer C
*Application in a steel industry

4. Integrated ML model for data analysis
4 head 3 strand Z-Mill
6 head 4 strand Cold rolling mill (CRM)

5. Sink
Data Set
Source
Data Set
Linked Service
Azure Blob
Storage
Source File
(Zipped
TSV)
Target File
(TSV)
Azure Data
Lake
Pipeline
Source Sink
CopyActivity for storing the data
1
2
5
4
3
Linked Service
Copy Activity
6
1 ls_ablob_covidreportingsa
2 ds_population_raw_gz
3 ls_adls_covidreportingdl
4 ds_population_raw_tsv
5 pl_ingest_population_data
6 Copy Population Data
StorageAccount: covidreportingsa
Container: population
File: population_by_age.tsv.gz
StorageAccount: covidreportingdl
Container: raw
File: population/population_by_age.tsv

7. Integration of ASRS system for improvement of Poor Efficiency & Un/Semi skilled manpower (Collaborative robots)
Picture has been taken from Jindal stainless steel limited (Jajpur plant, Odisha)
Manufacturer Name of ASRS: Armstrong limited
S.W.L of the crane – 100 Ton
Degree of freedom – 3, Travel Speed in each direction – 5-10 m/min
Max lifting height – 22 m, Girder type – Single, Span – 0- 35 m,
12V geared high torque DC servo motors (3),
Rack and pinion for arm y axis motion ,Sliding platform with pulley and belt for x and z axis motion
PLC with digital I/O
ASRS : Automated
storage &
Retrieval system

8. Side View Top View
Objective
•To increase storage capacity, security, labour productivity, Density, stock rotation, throuput & reduce labour cost
Procedure
•Start mains.
•Place object on the fork.
•Select storage or retrieval.
Storage Cycle
•If object is placed and storage is selected, select the storage location by pressing specified switches on the PLC.
•Motor moves in x axis depending on location.
•On hitting the limit switch z axis motor is triggered and depending on location it moves up or down.
•Then fork moves forward, places object on the rack, lift moves down and rack comes back simultaneously.
•Lift comes back to initial position.
Retrieval Cycle
•For retrieval select the rack number.
•Motor will move in x axis until hits one of the limit switches.
•Then as per the location z axis motor will move up or down and simultaneously fork will be extended.
•And then fork will retract and lift will come to its initial position.
•De-energizing mains will halt the whole program where ever required.

9. Two controllers we can use.
1.The PLC based system controller and the PLC based stacker crane controller.
2.The PLC based system controller is interfaced with PLC based stacker crane controller
through interface modules. These two controllers communicate through Profibus. Here
Profibus is used so that all the inputs and outputs can be connected in single cable for
easier and faster communication. The stacker crane controller is connected to several
sensors, limit switches to get physical inputs. The PLC based system controller is nothing
but the HMI (Human Machine Interface) screen. Once when the sever enters the rack
number for storing or retrieving operation the stacker crane controller senses the row
and column to which it has to perform the operation. The end limits of travel in all the
axes of movement are detected by heavy duty limit switches. The position of fork at
centre is also detected by limit switch. The sensors of P&D platform is used to sense the
presence or absence of pallet. The emergency switch is provided for any emergency
purpose like power failure and shuts down the whole system. The Reset option is used to
stop the crane at any position and return to its homing position.
The circuit diagram consists of power supply and programming part. It
contains a step down transformer, bridge rectifier, filtering capacitor,
voltage regulator, IR pair, ULN circuit, relays and PLC. In the power
supply circuit 230 volt 50 Hz AC supply is given to the transformer
which acts as a step down transformer. This stepped down AC voltage is
given to bridge rectifier which is converted into DC voltage. Further this
filtered DC voltage is given to a 7812 regulator that gives a constant 12
volt DC supply which is given to the IR pair. Whenever there is an
obstacle in the spacing of transmitter and receiver it will sense the
object and send signals to the ULN circuit. ULN is an IC chip which will
be acting a NOT operation. Therefore the supply will be reversed in the
ULN and is given to the relay which activates it.

10. • The motor operation is performed using PLC and relays. Triaxial operation is performed here that is, X axis, Y
axis and Z axis. Hence three motors are used to perform the operation. Here we have two relays for each axis
of direction. If we consider the X axis operation, common terminal of R1 is connected to the positive
terminal of the motor and common terminal of R2 is connected to negative of the motor. The normally
closed terminals of the both relays are short circuited and the normally open terminals of both relays are
also short circuited. The positive terminal of the power supply from the PLC is given to the normally open
terminal and the negative terminal of the power supply is given to the normally closed
Truth table of X directional motor
R1 R2 Motor Logic
0 0 No operation The common terminal will be in contact with normally closed terminal
0 1 Reverse
The common terminal of R2 will come in contact to normally open terminal and
since the common terminal is connected to negative of the motor, the motor
will rotate in reverse direction
1 0 Forward
The common terminal of R1 will come in contact to normally open terminal and
since the common terminal is connected to positive of the motor, the motor will
rotate in forward direction
1 1 No operation The common terminal will be in contact with normally closed terminal

11. This is the HMI screen which is developed using
Wonderware Intouch software. In Fig 7 we have
designed a control panel for store and retrieve
command. When the chamber number is entered and
store or exit option is clicked the crane operates
automatically and reaches that particular chamber and
performs the operation given. In the status display the
availability of pallets in each chamber will be indicated.
When the crane stops in a particular position that will be
indicated in position sensor display. Whatever process is
happening will be indicated in the process information
display panel
PLC (It’s a physical software) where as SCADA is system software