Chapter 1: Introduction to Wireless Rapid Inventory Access System
1.1 Background
In earlier times, inventories were small, and items could be located manually without much difficulty. However, with the passage of time, inventories have become extremely large and complex. Today’s modern warehouses and industrial stores are so huge that manual searching of items is almost impossible. This creates delays, confusion, and inefficiency in inventory management.
To overcome this problem, a Wireless Automatic Rapid Inventory Access System using ZigBee technology is proposed. This system allows quick and accurate access to items in large inventories and warehouses. It integrates a host computer with a Graphical User Interface (GUI) and uses ZigBee radios for wireless communication between the computer and inventory drawers.
1.2 Problem Statement
Manual inventory access in large industries leads to:
- Wastage of time in searching items.
- Confusion between office assistants and operators.
- Errors in fetching the correct item.
- Delays when assistants are unavailable.
Thus, an automatic wireless solution is necessary to minimize delays and improve efficiency.
1.3 History of Inventory Systems
In the past, smaller inventories were manageable manually. Larger inventories required additional manpower, but even then mistakes and miscommunication occurred. As industries expanded, manual methods became insufficient. This led to the need for automated electronic inventory systems, which reduce searching time and eliminate communication gaps.
1.4 Need of the Proposed Research Work
- Modern warehouses contain thousands of drawers.
- Manual searching wastes time and often creates confusion.
- Assistants may not always be present, causing further delays.
- An automated, wireless, and LED-based system is required to solve these challenges.
1.5 Significance of the Research
The proposed system ensures:
- Quick and error-free inventory access using glowing LEDs.
- Audio alarm alerts through a buzzer for assistants.
- Password-protected access via MATLAB GUI.
- Improved coordination without direct communication between operator and assistant.
1.6 Motivation for the Work
During training at Sony India, New Delhi, the inefficiencies of manual inventory access were observed:
- Long delays in fetching items.
- Frequent miscommunication between operator and assistant.
- Wrong items fetched due to confusion.
- Items forgotten if the assistant was busy.
This inspired the development of a wireless ZigBee-based inventory system with password security and LED-buzzer indication for error-free item retrieval.
1.7 Objectives of the Research
- To design and develop a rapid inventory access system to speed up retrieval.
- To develop a wireless inventory access system using ZigBee radios for efficient communication.
- To integrate password protection in the MATLAB GUI for authorized access.
- To create a user-friendly GUI with push buttons representing items.
- To raise an alarm through buzzer and LEDs for notifying assistants.
Chapter 2: Hardware Design of the Proposed System
The hardware consists of three major components:
- Microcontroller (PIC18F452)
- ZigBee module
- Power supply
2.1 Microcontroller – PIC18F452
Features:
- High performance with Flash memory.
- 32 KB code space, 1536 bytes RAM, 256 bytes EEPROM.
- Clock speed up to 40 MHz with PLL multiplier.
- USB interface support.
Peripheral Features:
- Multiple timers (Timer0, Timer1, Timer2, Timer3).
- High current source/sink.
- PWM output with resolutions up to 10-bit.
- Capture/Compare modules for real-time applications.
- SPI and I2C communication support.
2.2 ZigBee Module
ZigBee is a low-power, wireless communication protocol based on IEEE 802.15.4. It is widely used in wireless personal area networks (WPANs) due to its low cost, low energy consumption, and simple design.
ZigBee Device Types:
- Coordinator (ZC): Starts the network, assigns PAN ID.
- Router (ZR): Forwards data between devices.
- End Device (ZED): Low-power, simple node communicating with ZC/ZR.
Applications:
- Wireless home automation.
- Smart energy meters.
- Traffic and street light control.
- Industrial equipment monitoring.
ZigBee devices operate at 250 kbps (2.4 GHz), 40 kbps (915 MHz), and 20 kbps (868 MHz). They are configured using X-CTU software.
2.3 Power Supply Components
2.3.1 Transformer
Converts AC voltage levels (step-up or step-down). Works on the principle of Faraday’s Law of Electromagnetic Induction.
2.3.2 Voltage Regulator (LM7805)
- Converts varying DC voltage into stable 5V output.
- Three pins: Input, Ground, Output.
2.3.3 Diode
- Allows current in one direction only.
- Used in bridge rectifier design for converting AC to DC.
2.4 Light Emitting Diode (LED)
- Semiconductor device (Gallium Arsenide).
- Emits photons when electrons recombine.
- Color depends on semiconductor material.
- Represents inventory drawers in the proposed system.
2.5 Buzzer
- Works as an audio signaling device.
- Alerts assistant whenever an item is ordered via GUI.
Chapter 3: Software Development
3.1 mikroC for PIC Microcontroller
- ANSI compliant compiler.
- Built-in code editor and debugger.
- Large hardware libraries for PIC12, PIC16, and PIC18.
- Example codes for rapid development.
3.2 MATLAB for GUI Development
MATLAB Features:
- High-level technical computing language.
- Advanced 2D and 3D visualization tools.
- External interface support with C/C++ and Fortran.
- Interactive GUI building with GUIDE.
GUIDE (GUI Development Environment):
- Layout Design: Drag-and-drop components like push buttons, text boxes.
- Programming: Automatic MATLAB code generation with callback functions.
3.3 X-CTU for ZigBee Configuration
- Configures ZigBee modules as Coordinator and Router.
- Assigns addresses (DH, DL, SH, SL).
- Updates firmware (Coordinator AT, Router AT).
- Establishes point-to-point communication.
3.4 PCB Design and Fabrication
Using Eagle Software:
- Schematic Design: Represents circuit connections.
- PCB Layout: Optimized manual routing for minimum jumpers.
- Design Rule Check (DRC): Corrects PCB errors.
- Final Netlist Check: Ensures consistency with schematic.
PCB Design Rules:
- Place fixed components first.
- Larger components before smaller ones.
- Shortest possible conductor lengths.
- Components aligned in rows/columns for better maintenance.
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