Design and implementation of a PLC-based smart warehouse management system

In this thesis I. Built the smart warehouse management system to automate the process of moving and placing products onto storage racks. The main motivation, for my study is that many facilities still carry out storage work by hand. Manual work often leads to time loss, human errors and higher labor costs. To solve these problems I developed the warehouse management system with sensors and pneumatic equipment. I designed a system that has a conveyor line, a sensor, a vacuum picking mechanism, two pneumatic cylinders and a GMTSoft PLC unit. When a product reaches the detection point on the conveyor line the photoelectric sensor sends a signal to the GMTSoft PLC unit. The GMTSoft PLC unit stops the conveyor line. I linked the HMI interface with the PLC control using the PDesigner application. The HMI interface allows the operator to oversee the system and intervene manually when required. The HMI interface includes a login page, a system status display, manual control choices, and counter data. The design improves the system's utility for many applications and industrial environments. Upon reviewing the simulation results, I see that the model precisely recognizes products, coordinates movements efficiently, and performs the rack installation procedure flawlessly. The findings suggest that smart warehouse applications can be created with cost considerations. The system can function as a fundamental platform for project expansion.