A laboratory-scale 3-axis automated storage and retrieval system prototype for electronic component management

Sri Kusumastuti; M. Ihya’ Ulumuddin; Cleva Tusara Kumbalany; Sihono Sihono; Vinda Setya Kartika; Raditya Artha Rochmanto; Suryono Suryono; Aminuddin Rizal

doi:10.30811/jpl.v24i2.8148

A laboratory-scale 3-axis automated storage and retrieval system prototype for electronic component management

Sri Kusumastuti, M. Ihya’ Ulumuddin, Cleva Tusara Kumbalany, Sihono Sihono, Vinda Setya Kartika, Raditya Artha Rochmanto, Suryono Suryono, Aminuddin Rizal

Abstract

Efficient storage and retrieval of electronic components remain challenging in laboratory-scale environments due to reliance on manual handling. This study presents the development and experimental evaluation of a laboratory-scale three-axis Automated Storage and Retrieval System (ASRS) prototype designed for electronic component management. The proposed system uses a combination of servo and stepper motors to provide controlled motion along the X, Y, and Z axes. It is managed by a Programmable Logic Controller (PLC) integrated with a Human–Machine Interface (HMI). Manual operation is used for system calibration and motion adjustment, while automatic operation facilitates sequential storage and retrieval processes. We evaluated the system's performance by measuring positional accuracy and deviation at multiple target rack locations. The results show that the system achieves positioning accuracy of 84.62% - 95.38%, with absolute deviations between 0.3 and 1 cm. These findings demonstrate that the ASRS prototype is a feasible solution for effective laboratory-scale automation in storage applications and for PLC-based educational purposes.

Keywords

ASRS; PLC; HM;, servo motor; stepper motor

Full Text:

PDF

References

A. Edouard, S. Bourdin, and A. Brun, “Automated storage and retrieval systems: An attractive solution for an urban warehouse’s sustainable development,” Sustainability, vol. 14, no. 15, p. 9518, 2022, doi: 10.3390/su14159518.

B. Salah, S. A. Khan, I. Abunadi, and W. Abualfaraa, “Automated stacker cranes: A two-step storage reallocation method using simulation,” Processes, vol. 9, no. 1, p. 2, 2021, doi: 10.3390/pr9010002.

Y. Li, X. Li, and B. Y. Ekren, “Shuttle-based storage and retrieval system: A literature review,” Sustainability, vol. 14, no. 21, p. 14347, 2022, doi: 10.3390/su142114347.

M. Eder, T. Lerher, and M. Sraml, “Performance evaluation of SBS/RS with single-aisle shuttles,” International Journal of Advanced Manufacturing Technology, vol. 106, pp. 4161–4176, 2020, doi: 10.1007/s00170-019-04735-z.

W. Dong, X. Chen, and M. Chen, “ASRS design with variant 3D racks,” European Journal of Operational Research, 2024.

G. Lupi, M. Peron, and I. F. A. Vis, “Space efficiency and throughput in AVS/RS systems,” International Journal of Advanced Manufacturing Technology, vol. 131, pp. 1449–1466, 2024.

R. Chen, H. Yang, and J. Leung, “Retrieval request scheduling in shuttle-based ASRS,” Computers & Industrial Engineering, vol. 182, p. 109357, 2023, doi: 10.1016/j.cie.2023.109357.

R. Manzini, M. Gamberi, A. Regattieri, and A. Persona, “Design and control of automated storage and retrieval systems,” International Journal of Advanced Manufacturing Technology, vol. 28, no. 7, pp. 766–774, 2006, doi: 10.1007/s00170-005-0600-6.

K. J. Roodbergen and I. F. A. Vis, “A survey of literature on automated storage and retrieval systems,” European Journal of Operational Research, vol. 194, no. 2, pp. 343–362, 2009, doi: 10.1016/j.ejor.2008.01.038.

Y. Jaghbeer et al., “Automated order picking systems: Design and performance links,” International Journal of Production Research, vol. 58, no. 20, pp. 6520–6537, 2020, doi: 10.1080/00207543.2020.1716756.

M.-Y. Wei, C.-Y. Chuang, and C.-J. Wu, “Design and control of a 3-axis servo platform,” Energies, vol. 16, no. 10, p. 4208, 2023, doi: 10.3390/en16104208.

J. R. Mahmood and O. I. Khalaf, “PLC/HMI-based implementation of a real-time relaying laboratory,” Electronics, vol. 9, no. 1, p. 118, 2020, doi: 10.3390/electronics9010118.

F. Mo, D. Wang, B. Johansson, and T. Lundholm, “PLC orchestration automation for human–machine collaboration,” Computers in Industry, vol. 153, p. 103000, 2023, doi: 10.1016/j.compind.2023.103000.

M. Al-Yaman et al., “A modular PLC laboratory for hands-on industrial learning,” Engineering Science and Technology, an International Journal, 2025.

B. Y. Ekren and A. Akpunar, “Flexible vs. non-flexible shuttle travel policies in SBS/RS,” Sustainability, vol. 15, no. 1, p. 762, 2022, doi: 10.3390/su15010762.

Z. U. Rizqi et al., “Multi-objective simulation–optimization for integrated AS/RS planning,” Computers & Industrial Engineering, vol. 190, p. 109963, 2024, doi: 10.1016/j.cie.2024.109963.

Z. U. Rizqi et al., “Dynamic crane scheduling for green automated warehousing,” Computational Optimization and Applications, 2025.

M. Xu et al., “Flexible robotic grippers with magnetorheological materials,” Materials, vol. 17, no. 19, p. 4858, 2024, doi: 10.3390/ma17194858.

A. Alhijaily et al., “Multi-arm gantry system for cooperative manufacturing,” International Journal of Computer Integrated Manufacturing, vol. 37, no. 12, pp. 1408–1424, 2024, doi: 10.1080/0951192X.2024.2314567.

M. A. Koondhar et al., “The role of PLC in automation, industry, and education: A review,” International Journal of Engineering Research and Technology, vol. 12, no. 7, pp. 68–78, 2023.

M. Pekarcikova et al., “Educational robotics for Industry 4.0/5.0 using Wlkata Mirobot,” Machines, vol. 13, no. 9, p. 753, 2025, doi: 10.3390/machines13090753.

A. Edouard, S. Bourdin, and A. Brun, “Smart connected sensing with AS/RS,” Sustainability, vol. 14, no. 15, p. 9518, 2022.

Y. Li and X. Li, “AS/RS travel time with horizontal deployment in class-based storage,” IIE Transactions, 2025.

K. J. Roodbergen and I. F. A. Vis, “Travel time analysis of a new AS/RS concept,” Computers & Operations Research, vol. 32, no. 6, pp. 1515–1544, 2005, doi: 10.1016/j.cor.2003.12.008.

I. Battarra et al., “A design framework for shuttle-based automated storage and retrieval systems,” IFAC-PapersOnLine, 2024.

T. Nguyen, P. Luu, and J. Kim, “Integration of PLC-based ASRS with cloud monitoring for smart factories,” IEEE Access, vol. 13, pp. 134512–134523, 2025, doi: 10.1109/ACCESS.2025.134512.

R. Sharma and V. Kumar, “IoT-enabled warehouse automation using PLC and HMI,” Sensors, vol. 24, no. 8, p. 3022, 2024, doi: 10.3390/s24083022.

L. Wang, H. Zhang, and D. Yu, “Learning-based control framework for educational ASRS platforms,” IEEE Transactions on Learning Technologies, vol. 18, no. 2, pp. 145–157, 2025, doi: 10.1109/TLT.2025.1152309.

T. Lerher, “Modern automated storage and retrieval systems: A review,” Journal of Mechanical Engineering, vol. 62, no. 1, pp. 55–63, 2016, doi: 10.5545/sv-jme.2015.2856.

S. Zhang, Y. Guo, and J. Liu, “Design and performance analysis of a miniature automated storage and retrieval system,” International Journal of Advanced Manufacturing Technology, vol. 102, nos. 5–8, pp. 2141–2152, 2019, doi: 10.1007/s00170-019-03327-1.

DOI: http://dx.doi.org/10.30811/jpl.v24i2.8148