OPTIFORK

Abstract

This project presents the design and implementation of OptiFork, an autonomous warehouse robotic system aimed at improving efficiency and organization in modern warehouse operations. The system addresses key challenges associated with manual material handling, such as slow item retrieval, high labor dependency, and unstructured transactions that may lead to errors in inventory management. OptiFork integrates embedded control systems with intelligent navigation to enable automated retrieval and delivery of items from storage shelves to designated delivery points. The system employs a dual-controller architecture, utilizing an Arduino Mega as the main motion and execution controller, and an ESP32 module for wireless communication and interaction with the warehouse management interface. This architecture ensures reliable real-time control while supporting flexible communication with external systems. The robotic platform is equipped with DC motors with gearboxes for mobility, stepper motors for precise lifting and positioning, and multiple sensors including IR sensors, ultrasonic sensors, and an MPU6050 inertial measurement unit. These components enable accurate navigation, obstacle detection, and orientation control within the warehouse environment. Unlike fixed X–Y–Z automated storage systems, OptiFork operates as a mobile robot, offering greater flexibility and reduced infrastructure cost. A key feature of the system is its structured, non-random transaction mechanism. Item requests are received through a computer-based interface managed by the warehouse supervisor, then processed and executed by the robot based on predefined shelf locations and item types. After completing each delivery, the system updates the inventory database to reflect item movement, ensuring accurate stock tracking. Experimental testing demonstrates that OptiFork achieves reliable autonomous navigation, accurate item retrieval, and efficient delivery performance. The project highlights how low-cost embedded systems and modular mechanical design can be combined to create a scalable and cost- effective warehouse automation solution, contributing to faster operations, reduced human intervention, and improved overall warehouse management.