School of mechanical and Industrial
Engineering
Mechatronics Assignment
Group 2
Temperature-Controlled Smart Storage System (TSSS)
for Pharmaceuticals
Group members Id No
Bisrat Engida UGR/7862/14
Nahom Bilatu UGR/4636/14
Kaleab Bahta UGR/9509/14
Yohannes Deres UGR/5408/14
Muluken Aragaw UGR/4733/14
Submitted To: Mrs. Tewedaje
Submission Date: Nov 27/2024
Temperature-Controlled Smart Storage System (TSSS) for
Pharmaceuticals
Background
Temperature-Controlled Smart Storage System (TSSS) for Pharmaceuticals Background A pharmaceutical
company needs a Temperature-Controlled Smart Storage System (TSSS) to store temperature-sensitive drugs
and medical supplies in a large warehouse. The TSSS must maintain a stable temperature range and monitor
environmental parameters (e.g., humidity and air quality) to ensure the quality and safety of stored items. The
system should autonomously adjust cooling and ventilation based on real-time data from sensors, and alert staff
if conditions exceed safe limits. Key features include temperature monitoring, ventilation control, fault detection,
and power management.
The Temperature-Controlled Smart Storage System (TSSS) is a sophisticated solution designed to maintain the
quality and safety of temperature-sensitive drugs and medical supplies in a warehouse. Here's a more detailed
breakdown of the context model to provide clarity:
Here’s an expanded and highly detailed breakdown of the Temperature-Controlled Smart Storage System
(TSSS) context model, emphasizing every layer of functionality, interactions, and operational logic:
Context model
1. Actors and Their Responsibilities
1.1 Warehouse Management Staff
The human element overseeing the TSSS.
Responsibilities:
Monitor System Interface:
Use dashboards, mobile apps, or desktop interfaces to observe real-time temperature, humidity, and system
health.
Interpret visualizations like graphs, warnings, or trend analysis for proactive intervention.
Respond to Alerts:
When the system sends notifications (e.g., via SMS, email, or app), staff must take immediate action to
investigate the issue.
Tasks include physically checking equipment, addressing improper storage, or ensuring the system resumes
normal operation.
Log Interventions:
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Any manual corrections or responses to system alerts must be documented in the TSSS or WMS interface for
regulatory audits.
For example, if the cooling system fails temporarily, actions like “moved affected items to backup refrigeration”
must be logged.
1.2 Maintenance Technicians
Technical experts ensuring the system’s reliability and operational integrity.
Responsibilities:
Routine Checks:
Periodically inspect temperature, humidity, and air quality sensors for accuracy.
Check for calibration errors and replace sensors reaching end-of-life.
Repair and Maintenance:
Resolve faults in cooling or ventilation systems, such as fixing fans, replacing compressors, or updating control
unit firmware.
Backup Power Systems:
Ensure uninterrupted operations during power outages by maintaining batteries, UPS systems, and diesel/solar
generators.
2. Key Components
The TSSS consists of hardware and software systems working together to provide precise environmental control.
2.1 Sensors
Devices continuously monitor environmental parameters.
Types of Sensors:
Temperature Sensors:
Maintain the range of 15°C–30°C (common for most pharmaceuticals).
High-precision industrial-grade sensors ensure compliance with stringent pharmaceutical standards.
Humidity Sensors:
Monitor relative humidity levels to prevent excess dryness or moisture.
Example: DHT22 or advanced alternatives for industrial use.
Air Quality Sensors:
Detect particulate matter, harmful chemicals, or gases that may compromise storage safety.
Communication:
Sensors transmit real-time data to the control unit via wired or wireless protocols (e.g., I2C, Zigbee, or Wi-Fi).
2.2 Control Unit
The “brain” of the TSSS, making decisions based on sensor input.
Functions:
Data Acquisition:
Collects sensor data at preconfigured intervals (e.g., every second).
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Aggregates readings for analysis and decision-making.
Threshold Comparison:
Compares real-time data against safe ranges for temperature, humidity, and air quality.
For instance, if temperature > 30°C, triggers cooling action.
Autonomous Actions:
Activates systems (e.g., refrigeration or ventilation) when deviations occur.
Alerts staff via notifications for extreme breaches or faults.
2.3 Cooling System
Keeps the warehouse environment within the required temperature range.
Components:
Energy-Efficient Compressors:
Operate dynamically to save energy while maintaining temperatures.
Multi-Zone Cooling:
Different zones of the warehouse can have independent temperature controls for various product types.
Advanced Features:
Proportional-Integral-Derivative (PID) Control:
Allows fine adjustments by analysing how quickly the temperature approaches the target range.
2.4 Ventilation System
Ensures proper air circulation and quality.
Components:
Variable-Speed Fans:
Adjust airflow based on real-time air quality data.
Filters:
Remove particulate matter, allergens, or harmful gases. Filters are regularly cleaned or replaced during
maintenance.
2.5 Power Management System
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Guarantees uninterrupted operation.
Primary Power:
The warehouse relies on grid electricity for standard operations.
Backup Systems:
UPS (Uninterruptible Power Supply):
Ensures seamless transition to backup power during outages.
Generators:
Diesel or solar generators provide long-term support for extended power failures.
2.6 Data Logger
Records all environmental conditions and system actions for compliance and analysis.
Purpose:
Provides historical data for audits, troubleshooting, and regulatory reports.
Helps identify patterns, such as recurring faults or temperature trends.
Storage Options:
Local Storage: SD cards or hard drives.
Cloud Storage: Enables remote access and integration with analytics platforms.
3. External Systems
3.1 Warehouse Management System (WMS)
Integrates TSSS data for overall warehouse operations.
Offers analytics tools to track trends and optimize processes (e.g., identifying sections prone to temperature
fluctuations).
3.2 Notification Systems
SMS/Email:
Alerts sent through GSM modules like SIM800L for instant communication.
Mobile Apps:
Enable real-time monitoring and interaction with the TSSS remotely.
4. Inputs
Sensor Data:
Real-time readings for temperature, humidity, and air quality.
Threshold Parameters:
Predefined safe limits (e.g., 15°C–30°C, 40%–60% humidity).
Power Status:
Monitored by the power management system.
5. Operational Environment
Challenges:
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Power Outages:
Requires robust and reliable backup systems.
External Weather Conditions:
Drastic temperature or humidity changes can stress cooling/ventilation systems.
Equipment Failures:
Faulty sensors, cooling units, or fans can disrupt safe conditions.
6. Processes and Interactions
6.1 Environmental Monitoring
Sensors send data to the control unit every second or millisecond.
6.2 Environmental Adjustment
If a parameter exceeds its threshold:
Temperature deviation triggers the cooling system.
Humidity increase activates dehumidifiers or adjusts airflow.
6.3 Alert Notification
Alerts specify the type of breach, e.g., “Temperature below 12°C in Zone A”.
6.4 Fault Detection
Self-diagnostic routines identify sensor faults or equipment malfunctions.
6.5 Power Management
Automatically switches to backup systems during power outages.
Summary of Benefits
Enhanced Safety: Ensures pharmaceutical products are stored under optimal conditions.
Regulatory Compliance: Maintains logs and generates reports for audits.
Cost Efficiency: Prevents wastage of sensitive items due to environmental failures.
Real-Time Visibility: Keeps staff informed and enables prompt responses to issues.
Uninterrupted Operation: Reliable power backup ensures continuous functionality.
This detailed architecture ensures that the TSSS fulfils its purpose in safeguarding pharmaceuticals while
offering seamless integration with human operators and external systems.
2. Environmental Monitoring
Environmental monitoring is the foundation of the TSSS. It involves using advanced sensors to track critical
parameters like temperature, humidity, and air quality in real time. These parameters are vital for maintaining the
integrity of stored pharmaceuticals, which can degrade or become ineffective if conditions deviate from the safe
range.
Data Collection:
Sensors such as the DHT22, industrial-grade temperature sensors, and humidity modules are strategically
installed across the warehouse. The choice of sensor depends on precision requirements and the size of the
warehouse. For example, sensitive zones may use highly accurate sensors that comply with pharmaceutical
standards.
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The sensors capture readings at regular intervals (e.g., every 5 seconds), ensuring continuous monitoring. This
data includes details such as:
Current temperature in degrees Celsius.
Humidity levels as a percentage.
Air quality, measured using particulate matter levels (e.g., PM2.5 concentration).
Data Transmission:
The readings are sent to the control unit through a communication network. This can be wired (e.g., Ethernet) for
high reliability or wireless (e.g., ZigBee, LoRa) to reduce infrastructure costs and increase flexibility in sensor
placement.
Data Storage:
The system timestamps and stores the collected data locally (on SD cards) and/or on cloud servers. Cloud
storage enables advanced analytics and remote access, while local storage ensures redundancy in case of network
issues.
Continuous Monitoring:
The control unit processes incoming data in real time, cross-checking against predefined thresholds (e.g., 15°C–
30°C for temperature). Any anomaly triggers corrective actions or alerts.
2. Temperature and Humidity Control
Maintaining optimal temperature and humidity is critical for the stability of pharmaceutical products. This
function automates environmental control, ensuring deviations are corrected promptly.
Threshold Comparison:
As sensor data arrives, the control unit compares it with the safe operating range. For example:
Temperature: 15°C–30°C.
Humidity: 40%–70% relative humidity (RH). Any value outside these ranges is flagged as a deviation.
Cooling Adjustment:
If the temperature exceeds the upper limit:
The control unit increases the cooling system’s output proportionally to the deviation. For example:
At 31°C, the system activates a low-power cooling mode.
At 35°C, the compressor operates at maximum capacity to quickly reduce the temperature.
Multi-zone cooling ensures that only the affected zones are targeted, minimizing energy consumption.
If the temperature drops below the lower limit:
Cooling is reduced or stopped. If integrated, heaters may be activated to restore optimal conditions.
Humidity Regulation:
If humidity rises above the upper limit (e.g., 70% RH), dehumidifiers are activated.
Increased airflow through variable-speed fans reduces moisture effectively.
Conversely, if humidity drops below the lower limit (e.g., 40% RH), humidifiers may add moisture.
Feedback Loop:
After adjustments, the system monitors changes continuously to fine-tune operations until the conditions
stabilize.
3. Fault Detection and Maintenance
Fault detection ensures the system operates reliably by identifying hardware or software issues early. This
proactive approach minimizes downtime and reduces the risk of failures impacting storage conditions.
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1. Self-Diagnostics:
The system periodically checks the performance of sensors, cooling units, and ventilation fans. For example:
Sensors are tested for connectivity and accuracy.
Fans are monitored for speed and electrical consumption, which can indicate wear or damage.
2. Fault Detection:
When an issue is identified, it is categorized based on severity:
Minor Faults: A slightly inaccurate sensor reading may trigger a calibration request.
Critical Faults: A non-functional cooling unit or disconnected sensor is flagged immediately, as it poses a direct
threat to environmental control.
3. Alert Notification:
The system generates detailed alerts, such as:
"Zone B temperature sensor not responding."
"Fan speed below operational range in Zone C." Alerts are sent to maintenance staff through SMS, email, or
mobile apps.
4. Maintenance Scheduling:
Once alerted, technicians can prioritize repairs based on the fault’s severity. The system maintains logs of all
faults and resolutions for future reference.
4. Alert Notification
Prompt notification is critical for quick responses to environmental deviations or system faults. The alert system
is designed to ensure staff are informed immediately and can act without delay.
1. Threshold Monitoring:
The control unit continuously evaluates sensor readings against safe ranges. If a breach occurs (e.g., temperature
rises above 30°C), an alert is triggered.
2. Alert Creation:
The alert includes detailed information, such as:
The parameter that exceeded the threshold (e.g., temperature).
The specific zone affected (e.g., Zone A).
The current reading (e.g., 32°C).
The time of the breach.
3. Communication Channels:
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Alerts are delivered through multiple channels to ensure they reach the appropriate personnel:
SMS: Reliable for quick notifications.
Email: Provides detailed information.
Mobile Apps: Offers real-time monitoring and acknowledgment.
4. Escalation Mechanism:
If an alert is not acknowledged within a predefined timeframe, it is escalated to higher management.
5. Power Management
Detailed Explanation
Power management ensures the TSSS remains operational during outages, maintaining environmental stability
and protecting pharmaceutical products.
1. Primary Power Monitoring:
The system monitors grid electricity continuously, checking for fluctuations or outages.
2. Backup Activation:
During an outage:
The system switches to a UPS (Uninterruptible Power Supply) within milliseconds for short-term backup.
For extended outages, generators (diesel or solar) take over.
3. Battery Monitoring:
The UPS or generator batteries are monitored for charge levels and performance to ensure they are ready for use.
4. Alert Transmission:
Notifications inform staff about:
The power outage.
The backup system’s activation and estimated runtime.
6. Data Logging and Analytics
Data logging provides a historical record of environmental conditions and system performance, essential for
compliance, audits, and operational optimization.
1. Data Collection:
Sensor readings are collected continuously, with each reading timestamped.
2. Data Storage:
Local storage (e.g., SD cards) ensures accessibility during network issues.
Cloud storage enables advanced analytics and remote access.
3. Analytics and Insights:
Cloud-based tools analyse data to identify trends, such as recurring humidity spikes in specific zones.
Insights help optimize system settings and predict potential failures.
4. Access and Reporting:
Staff can access data via dashboards or generate reports for regulatory audits.
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7. System Integration
Detailed Explanation
The TSSS integrates with external systems for seamless operations and improved efficiency.
1. Warehouse Management System (WMS):
The TSSS shares environmental data and alert logs with the WMS. This integration allows for centralized
monitoring and trend analysis.
2. Mobile Applications:
Real-time data and controls are accessible through a mobile app, enabling remote management and quicker
decision-making.
3. Notification Systems:
The TSSS uses GSM modules like SIM800L to send SMS alerts, ensuring reliable communication even in areas
with poor internet connectivity.
3.Hardware Model for the Temperature-Controlled Smart Storage System (TSSS)
1. Component Selection
The selection of hardware components is based on the System Requirements Specification Sheet (SRSS). The
key considerations are reliability, precision, compatibility, and cost-effectiveness.
A. Sensors
1. Temperature Sensors (e.g., DHT22)
Purpose: Measures temperature to maintain the range of 15°C–30°C.
Reason for Selection:
High precision (±0.5°C accuracy) suitable for pharmaceutical-grade monitoring.
Affordable and widely available.
Alternatives: Industrial-grade sensors like the PT100 for environments requiring higher accuracy and durability.
2. Humidity Sensors (e.g., DHT22)
Purpose: Monitors relative humidity (RH) to ensure it stays between 40%–70%.
Reason for Selection:
Combines temperature and humidity sensing in a single unit.
Compatible with microcontrollers and low power consumption.
3. Air Quality Sensors (e.g., MQ135)
Purpose: Detects air contaminants (e.g., CO2, ammonia) that could affect product safety.
Reason for Selection:
Multi-gas detection capability.
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Economical for general air quality monitoring.
B. Control Unit
1. Microcontroller (e.g., Arduino Mega 2560)
Purpose: Serves as the brain of the system, processing sensor data and executing control actions.
Reason for Selection:
Multiple input/output (I/O) pins for managing several sensors and actuators simultaneously.
Easy to program and integrate with peripherals.
2. Alternative: Raspberry Pi 4
Selected for applications requiring advanced data processing or cloud integration.
Features include built-in Wi-Fi and GPIO pins for connecting multiple devices.
C. Actuators
1. Cooling Systems (e.g., Mini Refrigeration Units)
Purpose: Maintains the required temperature range.
Reason for Selection:
Compact and energy-efficient compressors.
Adjustable cooling intensity for multi-zone control.
2. Ventilation Systems (e.g., Variable-Speed Fans)
Purpose: Regulates airflow to stabilize humidity and air quality.
Reason for Selection:
Speed control provides precise adjustments based on sensor data.
3. Dehumidifiers
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Purpose: Removes excess moisture when humidity exceeds safe levels.
Reason for Selection:
Compact and low-energy consumption designs are ideal for pharmaceutical storage.
D. Power Management System
1. Uninterruptible Power Supply (UPS)
Purpose: Provides backup power during short outages.
Reason for Selection:
Ensures seamless operation during power interruptions.
2. Diesel/Solar Generators
Purpose: Long-term backup power for extended outages.
Reason for Selection:
Diesel generators are reliable for large-scale warehouses.
Solar generators are environmentally friendly for smaller facilities.
E. Communication Modules
1. GSM Module (e.g., SIM800L)
Purpose: Sends SMS alerts to staff.
Reason for Selection:
Affordable and supports SMS notifications in areas with limited internet access.
2. Wi-Fi Module (e.g., ESP8266)
Purpose: Enables remote monitoring via mobile apps.
Reason for Selection:
Easy integration with cloud services and real-time dashboards.
F. Data Storage
1. SD Card Module
Purpose: Stores historical environmental data for audits.
Reason for Selection:
Simple to use and reliable for local storage.
2. Cloud Storage Integration
Purpose: Provides remote access and advanced analytics.
Reason for Selection:
Scalable and supports complex reporting tools.
2. Integration Steps
Step 1: Sensor Integration
Connect temperature, humidity, and air quality sensors to the microcontroller’s analog or digital input pins.
Test each sensor’s output using diagnostic scripts to ensure accuracy.
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Step 2: Control Unit Configuration
Program the microcontroller with algorithms to process sensor data, compare it with thresholds, and trigger
corrective actions.
Set up real-time communication between the microcontroller and the cloud server or data logger.
Step 3: Actuator Setup
Wire the cooling system, fans, and dehumidifiers to the control unit via relays or motor drivers.
Configure the control logic to activate/deactivate actuators based on sensor readings.
Step 4: Power Management
Connect the primary power source, UPS, and generator to a smart switch.
Program the system to detect outages and switch seamlessly between power sources.
Step 5: Communication Module Integration
Install the GSM module for SMS notifications and test message delivery for alerts.
Configure the Wi-Fi module for mobile app integration and cloud communication.
Step 6: Data Storage
Connect the SD card module for local data logging.
Ensure the cloud storage API is properly linked with the control unit for real-time data upload.
Step 7: Testing and Calibration
Perform end-to-end testing under simulated conditions (e.g., temperature spikes, power outages).
Calibrate sensors and actuators for optimal performance.
3. Cost and Feasibility Analysis
A. Cost Breakdown
Sensors:
DHT22: 500 birr per unit.
MQ135: 1000 birr per unit.
Control Unit:
Arduino Mega 2560: 3000birr
Raspberry Pi 4: 6000birr
Actuators:
Cooling units: 20000–50000 birr each (depending on capacity).
Variable-speed fans: 2000–5000 birr each.
Dehumidifiers: 15000–30000 birr each.
Power Management:
UPS: 15000–30000 birr
Diesel generator: 50000–100,000 birr
Communication Modules:
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SIM800L GSM Module: 800 birr.
ESP8266 Wi-Fi Module: 600 birr
Data Storage:
SD card module: 1000 birr.
Cloud storage: Subscription-based, 1000–5000 birr per/month.
B. Feasibility Assessment
Technical Feasibility:
Components are readily available and compatible.
Proven technologies like Arduino and DHT22 ensure reliability.
Economic Feasibility:
Prototype costs are manageable, approximately 100,000–300,000 birr depending on warehouse size.
Long-term savings from automated monitoring and reduced product losses offset initial investment.
Operational Feasibility:
The system can be implemented in a standard warehouse with minimal modifications.
Cloud integration allows remote operation, reducing the need for on-site staff.
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