A Cargo Loading and Unloading Robot with IR Sensor-Based Obstacle Detection

Ong, Yu Hong (2026) A Cargo Loading and Unloading Robot with IR Sensor-Based Obstacle Detection. Final Year Project (Diploma), Tunku Abdul Rahman University of Management and Technology.

Text Full Text-Ong Yu Hong.pdf Restricted to Registered users only Download (7MB)

Abstract

This project was developed to address the logistical challenges faced by small and medium-sized enterprises (SMEs) struggling with high labor costs and the complex barriers of Industry 4.0. While large-scale automation exists, there is a significant gap in affordable, scalable solutions for smaller warehouse environments. This project aims to design and implement a low-cost autonomous mobile robot (AMR) capable of precise line-following and intelligent cargo handling. A key feature of the design is the multi-layered safety system, utilizing infrared (IR) sensors for close-range obstacle detection and navigation during the critical loading and unloading phases. The methodology involved an Arduino-based system integration, utilizing an IR sensor array for path alignment and proximity sensing, complemented by an HC-SR04 ultrasonic sensor for long-range safety. A servo-driven tilting mechanism was developed for autonomous unloading, powered by high-energy-density 18650 Li-ion batteries. Experimental results demonstrated a robust performance with an overall functional success rate of 87.5%, effectively validating the "Sense-Think-Act" engineering framework. The inclusion of IR-based detection ensured high-precision alignment and safety during cargo transfer. This study concludes that such affordable, sensor-integrated automation is technically feasible for SMEs, providing a strategic blueprint for enhancing operational efficiency through decentralized robotic intelligence