Advanced PLC-based Automation for Converging System and Warehousing

The increasing complexity of industrial convergence and warehousing operations presents challenges such as inefficient product handling, high manual intervention, and unoptimized space utilization. To address these issues, this research develops an advanced automation system integrating Programmable Logic Controllers (PLCs), Internet of Things (IoT) sensors, and AI-driven technologies. The designed framework automates critical functions, including product merging, collision avoidance, and real-time inventory tracking, ensuring seamless operations.In the convergence station, diffuse and capacitive sensors regulate product flow, preventing collisions and improving throughput.The intelligent warehouse utilizes AI-powered Automated Guided Vehicles (AGVs) with multi-function forks for enhanced stacking and picking. Space availability, alignment, and equipment status are monitored using IoT sensors to support predictive maintenance and less downtime. Siemens PLCs execute interlocked ladder logic with fail-safe mechanisms for continuous, error-free operations. Real-time dashboards enhance inventory visibility and operational decision-making.This automation system significantly reduces manual intervention, increases efficiency and optimizes warehouse space utilization. In addition, energy-efficient Automated guided vehicle planning promotes sustainability through decreased environmental impact. The solution lays the way for future innovations like digital twins and autonomous decision-making using AI, making it adaptable to changing manufacturing and logistics requirements.