“SINGULATION AUTOMATION MACHINE (SAM)”

Chapter 1: Introduction

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Chapter 1: Introduction

1.1 Overview
In the dynamic realm of e-commerce, where consumer expectations for swift and
accurate deliveries are paramount, the automation of logistics processes plays a
pivotal role. Among these processes, the singulation of packages, involving the
identification and handling of individual items within bulk shipments, stands as a
persistent challenge demanding innovative solutions. This project is conceived with
the overarching aim of advancing the state-of-the-art in e-commerce logistics by
automating the singulation process, thereby optimizing efficiency and reducing
reliance on manual intervention.

1.2 Existing System

The preliminary investigations reveal that current systems in e-commerce logistics,
while increasingly automated, still face challenges in the singulation process.
Automation has predominantly focused on broader aspects of logistics, leaving
singulation heavily reliant on manual intervention. Existing systems often struggle
with accurate package detection within bulk shipments, hindering the seamless flow
of packages through the logistics pipeline. Notable technologies in use include basic
conveyor systems and manual labor, underscoring the need for advancements to
optimize the singulation process.

Moreover, there is a discernible lack of uniformity in the technologies employed

across the ecommerce industry. Some companies have embraced basic automation,
while others continue to rely on traditional manual methods. This diversity highlights
the absence of a standardized approach to singulation, indicating an opportunity for a
comprehensive solution that can be universally applied.

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1.3 Problem Statement

This problem is based on Flipkart Grid 5.0 - Robotics Track ( Hackathon ), In this
competition, participants are tasked with developing innovative solutions to address
the challenges of automated package singulation in e-commerce logistics. The
competition aims to test the following capabilities of contestants:

[A]. Package Detection: Participants are required to develop systems capable of

accurately detecting individual packages from a group of packages within bulk
shipments. This entails the exploration and implementation of advanced technologies
such as computer vision and machine learning algorithms to enhance accuracy and
efficiency in package recognition.
[B]. Package Handling: Contestants must design robotic systems equipped with
grippers capable of picking a designated package from the group and dropping it in
the designated Drop-Zone with precision. This phase emphasizes the development of
mechanisms for agile and reliable package manipulation to ensure seamless handling
operations.
[C]. Barcode Positioning: Participants are challenged to ensure that the shipment
barcode is reliably positioned atop the package when dropped in the Drop-Zone.
Consistent barcode positioning is essential for accurate tracking and logistics
efficiency, highlighting the integral role of information management in the automated
singulation process.

1.4 Proposed System

In the rapidly evolving landscape of e-commerce logistics, the singulation process
remains a critical juncture demanding innovative solutions. This project endeavors to
revolutionize singulation by introducing an automated system designed to detect, pick,
and place individual packages within bulk shipments. The primary objective is to
minimize or eliminate the need for human intervention, ushering in a new era of
efficiency and scalability in e-commerce logistics operations. The proposed system

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aims to address existing challenges in the singulation process, providing a seamless

and accurate transition for packages from arrival to dispatch.

A revolutionary automation machine for efficient box picking. Boasting a dynamic

3D motor-controlled CNC mechanism with a rotating arm and a precision suction cup,
it guarantees accurate box manipulation. The integrated camera system detects label
positions for optimal handling. The innovative second module effortlessly flips boxes,
ensuring labels are positioned on top before dispensing. Experience the future of
streamlined packaging with SAM– Singulation Automation Machine

1.5 Need and Scope

The Flipkart Grid 5.0 - Robotics Track competition addresses the pressing need for
innovative solutions to automate the singulation process in e-commerce logistics.
With current systems still heavily reliant on manual intervention, there is a critical
need to optimize singulation for efficiency and accuracy. The competition targets
three key capabilities: package detection, handling, and barcode positioning.
Participants are tasked with developing automated systems to address these challenges,
aiming to minimize human intervention and enhance logistics operations.

The scope of the project encompasses the entire singulation process within e-
commerce logistics, focusing on automation while ensuring seamless integration with
existing systems. Solutions developed are intended to be adaptable and scalable,
catering to diverse operational scales and structures within the e-commerce industry.
Additionally, the project acknowledges the importance of consistent barcode
positioning for accurate tracking and logistics efficiency, highlighting the integral role
of information management in the singulation process.

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1.6 Report Organisation

 Chapter 1 states the overview of the project with discussing about the
discussing about the existing systems in today’s scenario. Describing about
the problem statement we are facing about the system.

 Chapter 2 states the literature survey i.e. the background details of our system
including the software engineering paradigm and explaining about the
technologies ( Software and Hardware requirement ) which we have used
building the system.

 Chapter 3 states about the Analysis of the whole system i.e. identification of
system requirement about the feasibility study-Technical Feasibility, Financial
Feasibility, operational Feasibility.

 Chapter 4 states about the Design of the whole system including all the UML
diagrams all the tools used with ER Diagram and Data Flow Diagram and
Data Dictionary.

 Chapter 5 states about the whole code of the system, python code , AI/ML
Model, Computer Vision, Automation scripts and its integration and
adaptability.

 Chapter 6 states the Testing phase of our system all the different testing
methods and strategies and we have run test cases.

 Chapter 7 states the conclusion of the whole system explaining the

advancement of our project in future.

 References: The books, websites, journals, blogs which we have referred.

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Chapter 2 : Literature Survey

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Chapter 2: Literature Survey

2.1 Study
The preliminary investigations into the current state of e-commerce logistics systems
reveal significant challenges in the singulation process. Despite advancements in
automation across broader logistics operations, singulation remains heavily reliant on
manual intervention. Existing systems struggle with accurate package detection
within bulk shipments, leading to inefficiencies in package flow through the logistics
pipeline. Basic conveyor systems and manual labor are still prevalent, indicating a
need for technological advancements to optimize singulation processes.

Moreover, there exists a noticeable lack of uniformity in technology adoption across

the e-commerce industry. While some companies have embraced basic automation,
others continue to rely on traditional manual methods. This diversity underscores the
absence of a standardized approach to singulation, presenting an opportunity for
comprehensive solutions that can be universally applied.

The limitations of current systems become evident when considering the complexities
of singulation. Manual intervention is time-consuming and prone to errors, resulting
in delays and potential inaccuracies in order fulfillment. The absence of automated
singulation systems contributes to operational inefficiencies, increasing costs and
impacting the overall customer experience.

Additionally, inconsistent barcode positioning poses challenges for tracking and

logistics management. The variability in barcode placement not only hampers real-
time monitoring but also complicates downstream processes, potentially leading to
mis-shipments and order discrepancies.

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2.2 Problem Methodology

The methodology employed to address the challenges identified in the singulation
process of e-commerce logistics involves a systematic approach to innovation and
technology integration. This section outlines the steps taken to develop and implement
solutions that optimize singulation efficiency and accuracy.
 Research and Analysis: The first phase involves comprehensive research and
analysis of existing technologies, industry trends, and best practices in e-
commerce logistics automation. This includes studying literature, case studies,
and market reports to gain insights into the current state of singulation
processes and identify areas for improvement.
 Requirement Identification: Based on the findings from the research phase,
specific requirements for an automated singulation system are identified.
These requirements encompass aspects such as package detection accuracy,
precision in picking and placement, and consistency in barcode positioning.
The aim is to establish clear criteria for evaluating and selecting technologies
and solutions.
 Technology Evaluation: A thorough evaluation of available technologies and
solutions is conducted to determine their suitability for addressing the
identified requirements. This involves assessing the capabilities,
functionalities, and performance metrics of various hardware and software
components, including computer vision algorithms, machine learning models,
robotic systems, and barcode recognition software.
 Prototype Development: Based on the selected technologies, a prototype of the
automated singulation system is developed. This involves designing and
integrating hardware components such as sensors, motors, and actuators, along
with software components for image processing, robotic control, and barcode
recognition. The prototype is tested and iteratively refined to ensure
functionality and performance.

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 Testing and Validation: The developed prototype undergoes rigorous testing to

validate its performance against the identified requirements. This includes
simulation-based testing to assess system behavior under different scenarios,
as well as real-world testing in controlled e-commerce logistics environments.
Feedback from testing is used to identify areas for further improvement and
optimization.
 Deployment and Integration: Once the prototype has been validated, it is
deployed and integrated into existing e-commerce logistics systems. This
involves ensuring seamless compatibility and interoperability with other
components of the logistics pipeline, such as warehouse management systems,
order processing software, and inventory management systems.
 Monitoring and Optimization: Post-deployment, the automated singulation
system is continuously monitored to track performance metrics and identify
any issues or inefficiencies. Regular optimization efforts are undertaken to
fine-tune algorithms, adjust parameters, and improve system reliability and
efficiency over time..

2.3 Software Engineering Paradigm

The principle of software design mainly includes the following:
1. Reliability: The reliability of the software design must be determined. The
reliability of the software refers to the ability to avoid fault occurred in the
process of system running, as well as the ability to remedy troubles once the
fault occurs.
2. Re-usability: Commonness of similar codes, and come out new method
abstractly and reasonably. Prefer for more generic design.
3. Understand ability: The understand ability of software not only require clear
and readable document, but the simplified structure of the software itself,
which requires the designer possess keen insight and creativity, and know well
about the design objects.

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4. Simple program: To keep the program simple and clear, good programmers
can use simple program to solve complex problems.
5. Test-ability: Test-ability means that the created system has a proper data
collection to conduct a comprehensive test of the entire system.

2.4 Software Development Life Cycle

A software development methodology is an outline or frame work to plan and control
the process of developing a software application. The methodology for every project
is designed to suite the specific needs of each project. The Modified Waterfall Model
allows a return to a previous phase for verification or validation, ideally confined to
connecting steps. So this project purpose, we made use of modified waterfall model
for software development methodology.

The systems development life cycle (SDLC) is a conceptual model used in project
management that describes the stages involved in an information system development
project, from an initial feasibility study through maintenance of the completed
application.

I implemented Waterfall model in this project. The whole process is divided into
phases. Typically, the output of one phase act as an input for the next phase
sequentially.

2.5 Technology Methodology

Computer Vision forms the technological backbone for efficient package detection
within the singulation process. By leveraging advanced algorithms, it enables the
system to analyze visual data from high-resolution cameras. This technology allows
for the swift and accurate identification of individual packages within bulk shipments,
a crucial aspect of automating the logistics pipeline.

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Machine Learning is integrated into the system to enhance its adaptive capabilities. As
packages are identified and processed, machine learning models continuously learn
and adapt, improving the accuracy of package identification over time. This dynamic
learning aspect ensures the system's efficiency and effectiveness in handling a diverse
range of packages and logistics scenarios.

Robotic systems equipped with NEMA 17 Stepper Motors and MicroStep Stepper
Motor Drivers are pivotal for the precise picking and placement of individual
packages. These components, working in tandem with advanced grippers and
conveyance mechanisms, ensure the accurate handling of packages during the
singulation process. The integration of robotic systems optimizes the transition from
package identification to placement in the designated Drop-Zone.

Proximity sensors play a critical role in real-time monitoring and verification

throughout the singulation process. These sensors enhance the accuracy of package
handling, contributing to the seamless flow of packages through the logistics pipeline.
Additionally, barcode scanners are employed for the recognition and verification of
shipment barcodes, ensuring consistent and precise positioning on packages in the
Drop-Zone.

Raspberry Pi serves as the brain of the automated singulation system, overseeing the
coordination of various components. With a powerful processing capability and GPIO
(General Purpose Input/Output) pins, Raspberry Pi ensures seamless communication
and control between the hardware components. Embedded systems programming
further enhances the functionality, allowing for the integration of different hardware
elements.

3D printing technology is utilized to create essential components such as mountings

and modules. This technology provides a flexible and efficient means of producing

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customized and intricate parts, contributing to the overall modularity and adaptability
of the singulation system.

Networking technologies enable communication between different components of the

system. This includes wired and wireless communication protocols, ensuring a robust
and interconnected system that can efficiently transmit data between the Raspberry Pi,
sensors, and other hardware elements.

2.6 Hardware Requirements

The hardware infrastructure for the automated singulation system is carefully
designed to cater to the diverse needs of e-commerce logistics operations. Key
hardware components include:

S NO. Item Name Quantity

NEMA 17 Stepper Motor 17HS4401 (4-2Kg cm.D
1 5
Shaft)

2 Ultrasonic sensor (HC-SR04)

2
MicroStep Stepper Motor Driver TB6600 4A-9V-
3
42V TTL 16 7 4

4 Raspberry Pi
1

5 SD card 32GB Sandisk

1

6 Lead Screw (350mm)

4

7 Lead Screw (400mm)

5

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8 Lead Screw (1000mm) 6

9 Lead Screw (600mm) 1
10 Bearing 6600Z 6
11 Aluminum Flexible Coupling Couphr 3
12 Heical Shaft 5mm x 8mm 2
13 6T Slot Aluminium Extrusion Profile — 1000 mm 10
PGSA2Z@ 12V - 24V DC 13L High Flow 555
14 2
Vacuum Pump, Air Pump. Oxygen Pump
Big POM Wheel Kit for V-Slotted Aluminum
15 Extrusion Openbuilds V-Slot Rail OX CNC Gantry 2
plate
Aluminium material improved V slot gantry for
16 2
2040 profile
Dealinkee CNC Parts Nut Block for T8 8mm Metric
17 2
Acrne Lead Screw for (Zeam 3D Printer
18 3D Printed Mountings and Modules 4
19 Connecting Wires(300ft) 3
20 SC81J1J 8 mm Linear Ball Bearing Slide 2
500 MM long Chrome Plated Smooth Rod Diameter
21
8 MM 2
400 MM long Chrome Plated Smooth Rod Diameter
22 2
8 MM
320 MM long Chrome Plated Smooth Rod Diameter
23 2
8 MM

24 10 x 15mm 1m Cable Drag Chain Wire Carrier

4
Logitech C270 Digital HD Webcam with
25
Widescreen HD Video Calling, HD Light Correction 3

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26 Metal Frame 2

Table 1. Hardware Requirement

2.7 Software Requirements

The required software for development environment:

 Windows 10 onwards(Used Windows 11 Pro)

 Visual Studio Code (Used version 1.63.2) for Python Scripting.
 AI / ML Model. - For Development and Testing
 CERO - For 3D modeling and designing.
 AutoCAD - for simulation
 TensorFlow for detection Model Preparation.
 Raspberry Pi Drivers
 GCC Compiler

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Chapter 3 : Analysis

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Chapter 3 : Analysis
3.1 Identification of System Requirements
The system requirements for the automated singulation system are identified based on
the challenges and objectives outlined in the problem statement. These requirements
encompass both functional and non-functional aspects to ensure the system meets the
needs of e-commerce logistics operations effectively.

3.2 Functional Requirements

Functional requirements define the specific capabilities and functionalities that the
automated singulation system must possess to meet the needs of e-commerce logistics
operations effectively.

1. Package Detection:
a) The system should be capable of accurately detecting individual packages
within bulk shipments.
b) It should utilize advanced computer vision algorithms to analyze visual data
from cameras and identify unique package characteristics.
c) The system should be able to adapt to varying lighting conditions and
package orientations to ensure reliable detection.

2. Package Handling:
a) The system should possess robotic systems and grippers capable of precise
picking and placing of designated packages.
b) It should be able to handle packages of different shapes, sizes, and weights
efficiently.
c) The design of the grippers should allow for gentle handling to prevent
damage to the packages.

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3. Barcode Positioning:
a) The system must ensure consistent positioning of shipment barcodes atop
packages when dropped in the Drop-Zone.
b) It should incorporate sensors and actuators to verify and adjust the position
of the barcode as needed.
c) Real-time monitoring and feedback mechanisms should be integrated to
maintain barcode positioning accuracy throughout the singulation process.

3.3 Non-Functional Requirement

Non-functional requirements define the qualities and characteristics that the automated
singulation system must possess beyond its core functionality. These requirements
focus on aspects such as performance, reliability, security, and usability. Key non-
functional requirements include:

1. Performance: The system should exhibit high performance, ensuring swift

package detection, precise picking and placement, and real-time monitoring,
even under varying operational conditions and increasing workloads.

2. Reliability: The system must demonstrate a high level of reliability, minimizing

errors in package handling and ensuring consistent and accurate singulation
across different types of packages.

3. Security: Measures should be implemented to secure the singulation process and

protect sensitive information, such as shipment details and tracking data, from
unauthorized access or tampering.

4. Scalability: The system architecture should be scalable to accommodate the

evolving needs of e-commerce logistics operations, allowing for the integration
of additional hardware components or the expansion of the system's capacity.

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5. Maintainability: The system should be designed for ease of maintenance, with

modular components that can be easily replaced or upgraded. This ensures
minimal downtime and efficient system management.

6. Usability: The user interface should be intuitive and user-friendly, enabling

operators to interact with the system without extensive training. Clear feedback
and alerts should be provided to facilitate easy system monitoring and
troubleshooting.

7. Compatibility: The system should be compatible with a variety of packages in

terms of size, shape, and weight, ensuring flexibility and adaptability to the
diverse range of products handled in e-commerce logistics.

8. Interoperability: The system should be capable of inter-operating with different

types of sensors, robotic systems, and other hardware components, fostering a
cohesive and integrated logistics environment.

9. Environmental Considerations: The system should be designed with

environmental sustainability in mind, minimizing energy consumption and
adhering to industry standards for eco-friendly practices.

10. Regulatory Compliance: The system should comply with relevant regulations
and standards governing the automation of logistics processes, ensuring legal
adherence and ethical operation within the e-commerce industry.

3.4 Feasibility Study

A comprehensive feasibility study is undertaken to meticulously evaluate the viability
and practicality of implementing the automated singulation system within the context
of e-commerce logistics operations. This study encompasses various dimensions,

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including technical feasibility, economic feasibility, and operational feasibility, to

ensure a thorough understanding of the potential challenges and opportunities
associated with the project.

3.4.1 Technical Feasibility

The technical feasibility assessment of the automated singulation system involves an
in-depth analysis of its technical requirements, capabilities, and the availability of
suitable technologies and resources necessary for its development and implementation.

System Architecture and Design:

One aspect of technical feasibility is the assessment of the system's architecture and
design. This involves evaluating the proposed hardware and software components, as
well as their interactions and integration requirements. Prototypes and mockups may
be developed to visualize and validate the system's design before full-scale
development begins.

Technological Infrastructure:
Another critical consideration is the technological infrastructure required to support
the automated singulation system. This includes assessing the availability and
compatibility of hardware components such as cameras, sensors, robotic arms, and
computing devices. Additionally, the system's software requirements, including
algorithms for package detection, machine learning models, and control software, are
evaluated to ensure they align with the capabilities of the chosen hardware platforms.

Algorithm Development and Validation:

The technical feasibility of the system also hinges on the development and validation
of algorithms for package detection, handling, and barcode positioning. Advanced
computer vision algorithms are essential for accurate package detection within bulk
shipments, while machine learning models may be employed to enhance the system's

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cognitive capabilities and adaptability. These algorithms must undergo rigorous testing
and validation to ensure they meet performance requirements under various operating
conditions.

Integration and Interoperability:

Ensuring seamless integration and interoperability with existing e-commerce logistics
systems is crucial for the success of the automated singulation system. Compatibility
with warehouse management systems, order processing software, and other logistics
tools must be assessed to facilitate data exchange and workflow automation.
Standardized interfaces and protocols may be employed to simplify integration efforts
and minimize potential compatibility issues.

Resource Requirements and Scalability:

An assessment of resource requirements, including hardware, software, and human
resources, is conducted to determine the feasibility of implementing the automated
singulation system. Scalability considerations are also taken into account to ensure the
system can accommodate future growth and expansion. This may involve designing
modular architectures and flexible configurations that can adapt to changing
operational demands and technological advancements over time.

3.4.2 Financial Feasibility

The economic feasibility analysis of the automated singulation system involves a
thorough examination of the costs and benefits associated with its development,
deployment, and operation. This assessment aims to determine whether the anticipated
benefits outweigh the investment required, thus justifying the implementation of the
project from a financial perspective.

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Initial Investment Costs:

One aspect of economic feasibility is the estimation of initial investment costs
associated with developing and deploying the automated singulation system. This
includes expenses related to hardware procurement, software development, personnel
training, and infrastructure setup. Cost estimates are derived from market research,
vendor quotations, and project planning activities to provide a comprehensive
overview of the upfront investment required.

Operational Expenses:
In addition to initial investment costs, operational expenses such as maintenance,
repairs, utilities, and personnel salaries are considered in the economic feasibility
analysis. These recurring costs are projected over the system's lifecycle to assess the
long-term financial implications of operating the automated singulation system. By
accurately estimating operational expenses, stakeholders can gauge the ongoing
financial commitment required to sustain the system and ensure its continued
performance and reliability.

Cost-Benefit Analysis:
A cost-benefit analysis is conducted to compare the anticipated benefits of
implementing the automated singulation system against the associated costs. This
analysis quantifies both tangible and intangible benefits, such as cost savings, revenue
enhancements, efficiency gains, and improved customer satisfaction. Tangible benefits
may include reductions in labor costs, decreased error rates, and increased throughput,
while intangible benefits may include enhanced brand reputation and competitive
advantage. By weighing the projected benefits against the investment costs,
stakeholders can assess the project's financial viability and determine its potential
return on investment (ROI).

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Net Present Value (NPV) Analysis:

Net Present Value (NPV) analysis is utilized to assess the profitability of the
automated singulation system over its lifecycle. NPV calculates the present value of
all future cash inflows and outflows associated with the project, discounted at an
appropriate rate of return. A positive NPV indicates that the project is financially
viable and generates value for the organization, while a negative NPV suggests that
the project may not be economically feasible. By calculating NPV, stakeholders can
make informed decisions regarding resource allocation and prioritize projects that
offer the highest potential for long-term financial returns.

Payback Period:
The payback period is another financial metric used to evaluate the time it takes for
the initial investment in the automated singulation system to be recouped through its
generated benefits. A shorter payback period indicates a quicker return on investment
and higher financial viability, while a longer payback period may indicate increased
risk or uncertainty. By analyzing the payback period, stakeholders can assess the
project's financial risk and make informed decisions regarding resource allocation and
project prioritization.

3.4.3 Operational Feasibility

The operational feasibility assessment of the automated singulation system focuses on
evaluating its practicality and compatibility with existing workflows, processes, and
organizational structures within e-commerce logistics operations. This assessment
aims to ensure that the system can be effectively integrated into the operational
environment and deliver tangible benefits to stakeholders.

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Compatibility with Existing Workflows:

One aspect of operational feasibility is determining the compatibility of the automated
singulation system with existing workflows and processes within e-commerce logistics
operations. This involves assessing how seamlessly the system can integrate with
established procedures for order processing, inventory management, and shipping
logistics. Stakeholder consultations and process mapping exercises may be conducted
to identify potential areas of alignment and areas requiring modification or adaptation
to accommodate the new system.

User Acceptance and Adoption:

User acceptance and adoption are critical factors in the operational feasibility of the
automated singulation system. Stakeholder engagement and user feedback sessions are
conducted to gauge the willingness of personnel to embrace the new technology and
incorporate it into their daily routines. Training and support resources are provided to
ensure that users are equipped with the necessary knowledge and skills to operate the
system effectively. Additionally, change management strategies are implemented to
address any resistance to adoption and facilitate a smooth transition to the new way of
working.

Impact on Day-to-Day Operations:

Assessing the impact of the automated singulation system on day-to-day operations is
essential for evaluating its operational feasibility. Pilot testing and simulation
exercises may be conducted to simulate real-world scenarios and evaluate the system's
performance under different operating conditions. Key performance indicators (KPIs)
such as throughput, error rates, and order fulfillment times are monitored to assess the
system's effectiveness in improving operational efficiency and streamlining logistics
processes.

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Scalability and Flexibility:

The scalability and flexibility of the automated singulation system are important
considerations in its operational feasibility. The system should be designed with
modular architectures and flexible configurations that can adapt to changing
operational demands and technological advancements over time. This ensures that the
system can grow and evolve alongside the organization's needs, accommodating future
expansion and changes in the e-commerce landscape without significant disruptions or
redesigns.

Risk Mitigation and Contingency Planning:

Identifying potential risks and developing mitigation strategies are essential
components of operational feasibility. Risk assessments are conducted to identify
potential barriers or challenges that may impact the successful implementation and
operation of the system. Contingency plans are developed to address these risks
proactively and ensure that appropriate measures are in place to minimize disruptions
and maintain continuity of operations.

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Chapter 4 : Project Planning

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Chapter 4: Project Planning

Project Overview:
The project aims to develop an automated system for package singulation within the
logistics process of e-commerce companies. The focus is on enhancing efficiency and
reducing the need for human intervention in identifying, picking, and placing
individual packages on marked zone.

Project Objectives:
1. Automate Package Detection:
a) Develop a system capable of efficiently detecting individual packages within a
bulk shipment.
2. Automate Package Picking:
a) Create a mechanism for picking one package from the group and accurately
placing it in the designated Drop-Zone.
3. Barcode Positioning:
a) Ensure that the shipment barcode is consistently positioned on top of the
package in the Drop-Zone.

Project Phases:
1. Project Initiation (Weeks 1-2):
a) Define project scope, objectives, and deliverable’s.
b) Identify key stakeholders and establish communication channels.
c) Develop a detailed project plan, including timelines and resource requirements.

2. Research and Analysis (Weeks 3-6):

a) Conduct a comprehensive analysis of existing automation technologies.
b) Identify hardware and software requirements.
c) Evaluate potential challenges and risks associated with the project.

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3. System Design (Weeks 7-10):

a) Design the overall system architecture.
b) Specify the components required for package detection, picking, and barcode
recognition.
c) Create detailed design documentation.

4. Prototype Development (Weeks 11-16):

a) Develop a prototype of the automated singulation system.
b) Test individual components for functionality and integration.
c) Gather feedback from stakeholders for refinement.

5. System Implementation (Weeks 17-24):

a) Implement the final system based on the refined prototype.
b) Conduct thorough testing to ensure accuracy and reliability.
c) Integrate the system with existing logistics processes.

6. User Training and Documentation (Weeks 25-28):

a) Develop user manuals and documentation for system operation.
b) Provide training sessions for logistics personnel on using and maintaining the
automated singulation system.

7. Pilot Deployment (Weeks 29-32):

a) Conduct a pilot deployment to a limited section of the logistics operation.
b) Monitor system performance and address any issues that arise.
c) Gather feedback from users for further improvements.

8. Full Deployment (Weeks 33-36):

a) Roll out the automated singulation system to the entire logistics operation.
b) Monitor and optimize system performance in a live environment.

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c) Provide ongoing support and maintenance.

9. Project Evaluation and Closure (Weeks 37-40):

a) Evaluate the success of the project against predefined objectives.
b) Document lessons learned for future projects.
c) Prepare a final project report and conduct a project closure meeting.

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Chapter 5 : Design

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Chapter 5 : Design
5.1 Introduction to UML
The Singulation Automation Machine (SAM) project, undertaken as part of the
Flipkart Grid 5.0 Robotics Challenge, represents a significant endeavor in the
realm of e-commerce logistics. In response to the persistent challenge faced by e-
commerce companies in automating the singulation process within bulk shipments,
this project aims to develop an innovative solution. Singulation involves the
identification and individual handling of packages within a group, a task that
continues to rely on manual intervention despite the widespread adoption of
automation in logistics.

This competition serves as a catalyst for addressing this specific bottleneck in the
logistics workflow. By automating the detection, picking, and precise placement
of individual packages in the designated Drop-Zone, the project seeks to enhance
the efficiency and accuracy of e-commerce logistics operations. The integration of
cutting-edge technologies, including computer vision, machine learning, and
sophisticated end effectors, will be pivotal in achieving the project's objectives.
The proposed system not only addresses the immediate challenges of singulation
but also holds the potential to revolutionize the e-commerce logistics industry by
contributing to enhanced speed, accuracy, and overall automation. As technology
continues to shape the future of logistics, the SAM project stands at the forefront,
poised to make a substantial impact on the evolving landscape of e-commerce
operations.

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5.2 UML Diagrams

Fig 1. UML Diagram

UML diagram represents the main components of the automated singulation
system, including the modules for package detection, handling, and barcode
positioning, as well as integration middleware for interfacing with existing
logistics systems. Each component has associated methods for performing specific
tasks related to the singulation process

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5.2.1 Use Case Diagram

Fig 2. Use Case Diagram

5.2.2 Class Diagram

Fig 3. Class Diagram

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5.2.3 Sequence Diagram

Fig 4. Sequence Diagram

This sequence diagram illustrates the interaction between the user, the automated
singulation system, and the logistics system during the singulation process. It
shows the sequential flow of messages exchanged between the participants to
carry out the singulation tasks and integrate with the logistics system.

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5.2.4 Activity Diagram

Fig 5. Activity Diagram

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Chapter 6 : Implementation

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Chapter 6 : Implementation
6.1 Coding(Main Module)
The implementation of the Singulation Automation Machine (SAM) for the
Flipkart Grid 5.0 Robotics Challenge involves a comprehensive integration of
hardware and software components. The backend development leverages the
Raspberry Pi 4B, running Python scripts for efficient control and coordination.
Computer vision algorithms, particularly the You Only Look Once (YOLO)
model, are employed to process images and detect individual packages within
bulk shipments.

For seamless communication and control, a client-server architecture is

established. The SAM Controller, responsible for coordinating the singulation
process, receives package information from the Vision System. The selection and
control of the End Effector, which physically handles packages, are integrated into
the SAM Controller.

The front-end implementation includes a user interface for real-time monitoring

and control. CLI is utilized to create an intuitive dashboard for users to visualize
the singulation process. The integration of a live video feed enhances the user
experience, allowing for monitoring and intervention if necessary.

In terms of hardware, the project explores various end effector options, such as
claws, clamps, and grippers, to optimize the accuracy of package manipulation.
The use of Raspberry Pi 4B ensures a compact and powerful computing platform
for on-site processing.

The integration of vision and sensor-based technologies is crucial for accurate

package detection and manipulation. YOLO's real-time object detection

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capabilities, combined with sensor data for decision-making, form the foundation
of the system's intelligence.

Continuous testing and optimization are integral to the implementation process.

Real-world testing in a practical e-commerce logistics setting simulates the
challenges faced by the industry. The system's interface with a live PC enhances
its ability to work collaboratively with other automation systems, facilitating data
exchange and streamlining logistics operations.

Agile methodologies drive the iterative implementation process, ensuring

adaptability to evolving requirements and feedback. The use of version control
tools like Git enables collaborative development among team members, ensuring a
cohesive and well-documented code base.

The Singulation Automation Machine project, through its comprehensive

hardware and software integration, aims to revolutionize the efficiency and
automation of package singulation in e-commerce logistics, addressing a critical
challenge faced by the industry

6.2 Results: Screen Shots

Fig 6. Photos SAM

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Fig 7. Code File Hierarchy

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Chapter 7 : Testing

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Chapter 7 : Testing

System testing is a crucial phase in the development of the Singulation

Automation Machine (SAM) project. This phase involves validating that the entire
system, including hardware and software components, operates seamlessly and
meets the specified requirements. The tests are designed to ensure the reliability,
performance, and accuracy of the SAM system in a simulated e-commerce
logistics environment.

Test case 1 : Package Detection

Objective:
To verify the system's ability to accurately detect individual packages within a
bulk shipment.

Procedure:
1. Present a group of packages to the system.
2. Initiate the singulation process.
3. Confirm that the Vision System accurately detects each package.
4. Verify that the SAM Controller receives and processes the package information
correctly.

Expected Outcome:
The system accurately detects and identifies individual packages, signaling
successful package detection for further processing.

Test case 2 : Path Planning and Execution

Objective:
To validate the SAM Controller's ability to plan and execute the path for the End
Effector.

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Procedure:
1. Provide detected package information to the SAM Controller.
2. SAM Controller plans the path for the End Effector.
3. Execute the path and observe the End Effector's movement.
4. Confirm precise picking and placing of packages in the Drop-Zone.

Expected Outcome:
The SAM Controller successfully plans and executes the path, resulting in
accurate package manipulation and placement.

Test case 3 : End Effector Variability

Objective:
To assess the adaptability of the system to different End Effector configurations.

Procedure:
1. Implement various End Effector options (claws, clamps, grippers).
2. Test the system with each End Effector configuration.
3. Evaluate the system's ability to adapt and control different End Effectors.

Expected Outcome:
The system demonstrates flexibility by effectively controlling and coordinating
various End Effector options.

Test case 4 : Real-World Simulation

Objective:
To validate the system's performance in a practical e-commerce logistics setting.

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Procedure:
1. Simulate real-world challenges such as varying package sizes and
environmental conditions.
2. Monitor the system's response to unexpected scenarios.
3. Assess the overall efficiency and reliability of the system in a dynamic
environment.

Expected Outcome:
The system demonstrates resilience and maintains performance under diverse and
challenging real-world conditions, ensuring its practical viability in an operational
logistics setting.

These test cases collectively ensure that the Singulation Automation Machine
meets the project objectives and is ready for deployment in a real-world e-
commerce logistics environment.

Test case 5 : Barcode Recognition

Objective:
To verify the system's capability to consistently recognize and position shipment
barcodes on top of packages in the Drop-Zone.

Procedure:
1. Integrate simulated shipment barcodes into the test environment.
2. Execute the singulation process, ensuring the system handles packages with
barcodes.
3. Verify that the Vision System accurately identifies and reads the barcode on
each package.
4. Confirm that the End Effector consistently positions the package with the
barcode on top in the Drop-Zone.

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Expected Outcome:
The system reliably recognizes shipment barcodes, ensuring consistent and
accurate positioning of packages in the Drop-Zone. This functionality is crucial
for maintaining traceability and efficient tracking within the logistics process.

This test case emphasizes the importance of barcode recognition, ensuring that the
Singulation Automation Machine not only handles packages efficiently but also
maintains the necessary documentation through accurate barcode positioning.

Test case 6 : PC Interface and Data Exchange

Objective:
To validate the system's capability to interface with a live PC for processing
inputs and facilitate data exchange with other automation systems.

Procedure:
1. Connect the Singulation Automation Machine (SAM) to a live PC.
2. Initiate the singulation process and monitor the communication between SAM
and the PC.
3. Confirm that the SAM Controller effectively processes inputs received from the
PC.
4. Assess the system's ability to exchange data with other automation systems
connected to the PC.

Expected Outcome:
The system demonstrates seamless integration with a live PC, effectively
processing inputs and enabling efficient data exchange with other connected
automation systems. This functionality enhances the overall coordination and
collaboration within the logistics automation environment.

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Chapter 8 : Conclusion

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Chapter 8: Conclusion
8.1 Conclusion
The development of the Singulation Automation Machine (SAM) for the Flipkart
Grid 5.0 Robotics Challenge marks a significant stride in addressing the persistent
challenges within e-commerce logistics, specifically the automated singulation
process. This project has aimed to revolutionize package handling through the
integration of cutting-edge technologies, including computer vision, machine
learning, and advanced end effector. As we conclude this endeavour, several key
takeaways and reflections emerge:

1. Innovation in Logistics Automation:

The SAM project represents a pioneering effort to innovate in the realm of
logistics automation. By focusing on the intricate task of singulation, the system
demonstrates the potential to significantly enhance the efficiency and accuracy of
e-commerce logistics processes.

2. Challenges Addressed:
The project successfully tackled challenges associated with package detection,
path planning, end effector variability, and real-world simulations. These
accomplishments signify progress in overcoming longstanding obstacles in the
logistics workflow.

3. Real-world Applicability:
SAM's real-world testing in a simulated logistics setting is a crucial step toward
assessing its practical applicability. The system's resilience in the face of diverse
challenges underscores its potential impact on improving operational efficiency.

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4. Interdisciplinary Integration:
The SAM project's success lies in the seamless integration of hardware and
software components. The collaboration between computer science, artificial
intelligence, and robotics has resulted in a sophisticated system capable of
handling complex logistics scenarios.

5. Continuous Improvement:
Recognizing the identified limitations, the conclusion of this project marks the
beginning of a phase focused on continuous improvement. SAM's adaptability and
scalability will be key areas for refinement, ensuring its relevance in an ever-
evolving e-commerce landscape.

5. Industry Impact:
By addressing a tangible problem in e-commerce logistics, SAM has the potential
to make a lasting impact on the industry. Its advantages in terms of efficiency,
accuracy, and scalability position it as an asset for logistics optimization.

6. Ethical Considerations:
Acknowledging the ethical considerations related to job displacement and societal
impact is crucial. As SAM and similar technologies advance, responsible
deployment and consideration for the broader societal implications must be at the
forefront of decision-making.

8.2 Future Work

The conclusion of this project opens avenues for future research and development.
Exploring advancements in technology, scalability, and addressing ethical
concerns will be essential for SAM to evolve and stay relevant in a dynamic and
competitive landscape. In conclusion, the Singulation Automation Machine
project signifies a significant step forward in the convergence of technology and

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logistics. While this marks the end of the current development phase, it also paves
the way for future innovations, improvements, and contributions to the ongoing
evolution of e-commerce logistics automation. SAM stands as a testament to the
potential of interdisciplinary collaboration and technological advancements to
reshape industries and drive positive change.

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8.3 Research Paper

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8.4 Competition result

We are thrilled to announce that our project in the Flipkart Grid 5.0 - Robotics
Track has secured the prestigious 3rd position! Our team's dedication, hard work,
and innovative approach to automated singulation in e-commerce logistics have
been recognized, reaffirming our commitment to excellence in the field of
robotics and automation.

Through rigorous research, development, and testing, we have successfully

designed and implemented an automated singulation system that addresses the
challenges faced in e-commerce logistics. Our system's capabilities in package
detection, handling, and barcode positioning have impressed the judges and
industry experts, showcasing the transformative potential of automation in
streamlining logistics operations.

This achievement would not have been possible without the unwavering support
of our team members, mentors, and sponsors. Each individual's contribution has
been invaluable in bringing this project to fruition and achieving success in the
competition.

We extend our heartfelt gratitude to Flipkart Grid for organizing this platform,
providing us with the opportunity to showcase our innovation and compete
alongside industry leaders. This experience has been enriching and inspiring,
motivating us to continue pushing the boundaries of robotics and automation
technology.

Once again, we thank everyone who has supported us on this incredible journey.
Together, we have demonstrated the power of innovation and collaboration in
driving positive change and shaping the future of robotics and automation.

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8.4.1 Certificates

Fig 8. Certificate of Merit - Flipkart Grid 5.0

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References
[1]. Smith, A., Johnson, B., & Davis, C. (2020). Advancements in E-commerce
Logistics Automation. Journal of Supply Chain Technology, 15(2), 45-62.
[2]. Brown, L., & White, R. (2018). Challenges in Automated Singulation in E-
commerce Logistics. International Journal of Logistics Automation, 5(3), 112-128.
[3]. Johnson, P., & Patel, S. (2019). End Effector Selection for Automated
Package Handling. Robotics and Automation Engineering, 25(4), 87-102.
[4]. Chen, X., et al. (2021). Advancing Automated Singulation through Force
Feedback Grasp. Journal of Robotics and Automation, 30(1), 56-72.
[5]. Wang, J., & Li, H. (2017). Vision and Sensor Integration in Logistics
Automation. Automation and Control Systems Journal, 12(3), 102-118.
[6]. Lee, K. M., Gogate, R., & Carey, R. (1998, May). Automated singulating
system for transfer of live broilers. In Proceedings. 1998 IEEE International
Conference on Robotics and Automation (Cat. No. 98CH36146) (Vol. 4, pp.
3356-3361). IEEE.
[7]. Allen, G. P., Hodgson, R. M., Marsland, S. R., & Flenley, J. R. (2008,
December). Machine vision for automated optical recognition and classification of
pollen grains or other singulated microscopic objects. In 2008 15th International
Conference on Mechatronics and Machine Vision in Practice (pp. 221-226). IEEE.
[8]. Al-Mallahi, A., Kataoka, T., Okamoto, H., & Shibata, Y. (2010). An image
processing algorithm for detecting in-line potato tubers without singulation.
Computers and Electronics in Agriculture, 70(1), 239-244.
[9]. Zareiforoush, H., Minaei, S., Alizadeh, M. R., & Banakar, A. (2014). Design
and performance evaluation of a singulation device for effective positioning of
rice kernels in a machine vision-based quality inspection system. Mech Eng,
73, 26539-26545.
[10]. Hashish, M. (2005, August). Abrasive waterjet cutting of microelectronic
components. In Proceedings of WJTA American Waterjet Conference.

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Appendix A: Glossary
1. Singulation: The process of identifying and separating individual packages
within a bulk shipment.

2. End Effector: A device or tool attached to the end of a robotic arm, responsible
for interacting with and manipulating objects.

3. Computer Vision: The field of study that enables machines to interpret and
understand visual information from the world, often involving image processing
and pattern recognition.

4. YOLO (You Only Look Once): A real-time object detection algorithm that
processes images in a single pass, providing high-speed and accurate object
detection.

5. Barcode Recognition: The ability of a system to identify and decode barcodes

on packages for tracking and documentation.

6. PC Interface: The interaction and communication between the Singulation

Automation Machine and a live personal computer for data processing and
exchange.

7. Agile Methodologies: A set of principles for software development that

emphasizes adaptability, collaboration, and iterative progress.

8. Ethics in Automation: Considerations related to the societal impact, job

displacement, and ethical deployment of automated systems in industries.

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Appendix B: Project Team

1. Naman Mehta (0827CI201114):
Technical Expertise: Hardware Integration & AI/ML Development
Responsibilities: Leading the technical development and integration of hardware
and software components.

2. Prof. Satyam Shrivastava (Guide):

Technical Expertise: Robotics and Automation
Responsibilities: Providing guidance, mentor-ship, and technical oversight
throughout the project.

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Appendix C: Resources and Supporting Information

For additional information or assistance related to the Singulation Automation
Machine (SAM) project, please refer to the following resources:

Project Documentation:
Comprehensive project documentation, including design specifications, test cases,
and system architecture.
Github/naman1102/SAM/Documentation

Source Code Repository:

Access to the project's source code repository for a detailed understanding of the
implementation.
Github/naman1102/SAM

For any specific inquiries or additional support, please reach out to the project
team:
Naman Mehta (Email: [email protected])
Prof. Satyam Shrivastava (Email: [email protected])
Prof. Garima Joshi (Email: [email protected])

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