IIoT Enabled Smart Logistics Rack for Automobile Assembly Automation

Overview

The smart IIoT logistics rack aims to smartly monitor, indicate, and analyse data related to product status, weight and aid in the optimal workflow in the environment.

The goal of this project is to enabled an automated system that monitors and indicates any item of use in an automotive industry setting, for the employees to quickly identify and replenish and optimally use the given item. This can range from nuts and bolts to actual large car parts, all in the form of a simplified system that handles vast amounts of weight data wirelessly.

Objectives

The whole system development was a challenge involving microcontroller communication with a. cloud
server via MQTT, custom fitted PLA fabricated parts for device housing and display fastening, along
with sensor holding, and an accurate replica of the ramp and bin system for sliding. Along with this, the
appropriate image display and the display of data on the server, as well as LED indication of color for
timing data was crucial.

Approach

• The initial setup of system interactions was key to visualize which component plays what role
• To manage the Volvo Group requirements, ESP32s and Azure S erver access was acquired
• The system of the bin and the ramp was design as a flowchart mechanic, along with accompanied
code for the microcontrollers, and the firmware, or boot loading and other related operations.
• Existing processes and products related to MQTT, ESP32 functioning, firmware of code was
studied. In addition, the magtag circuit layout was optimized to fit in existing schematics
• The sponsor Mi4 lab was studied to understand the bin ramp setup of existing manual domains,
and in addition, the rack dimensions were appropriated
• CAD models of the PLA prints and other visualizations on the ramp lip were made
• The enclosure, U-bracket and pressure plate was fabricated, and the ramp was manufactured
• The testing was done in 2-3 stages per prototype to tweak the key components with slight mods
• The data generated was seen on the plot as a gram value, tallied with the output from the ESP32

Outcomes

The ultimate goal and outcomes observed
of use to the Volvo Group Automation is:
• The sponsor will save about $700 per
bin due to this project
• Manufacturing and production times
should reduce twofold
• The project aims to reduce
procurement, replacement, and
assembly times
• The project resulted in a very
streamlined and ideal monitoring system
for a whole database of parts with
minimal sensors and processing
• The project also involved a very intuitive
sense of operation, with minimal
adjustments to run and power it.