🚜 Forklift-Mounted RFID Reader System

A robust, industrial-grade RFID-based asset tracking system designed for real-time inventory management in warehouse environments. This project integrates embedded hardware and full-stack web technologies to automate and optimize warehouse logistics using a forklift-mounted RFID reader.

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📌 Project Overview

This system enables forklifts to detect RFID-tagged goods during pallet movement and automatically update inventory data via Wi-Fi to a centralized web dashboard. It improves warehouse efficiency by minimizing manual data entry and ensuring accurate, real-time inventory tracking.

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🔧 Key Features

• 📡 RFID Tag Detection: High-frequency (13.56 MHz) RFID tag scanning using PN532.
• 🧠 Embedded Controller: ATmega328P-based control for RFID and communication tasks.
• 🌐 Wi-Fi Integration: ESP8266 transmits data wirelessly to backend server.
• 🖥️ Web Dashboard: Real-time inventory tracking and management via React frontend and Express + PostgreSQL backend.
• 🔩 Custom Enclosure & PCB: Vibration-resistant, forklift-compatible hardware with modular design and test-point access.

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🧠 System Architecture

[RFID Tag]
    ↓
[PN532 Reader] ←→ [ATmega328P MCU] ←→ [ESP8266 WiFi Module] → [Web Server]
                                                       ↓
                                               [PostgreSQL Database]
                                                       ↓
                                               [React Web Dashboard]

🎬 Video Demonstration

The video demonstration for our RFID reader can be viewed from here

⚙️ Technologies Used

🖥️ Hardware

• ATmega328P (QFP)
• PN532 RFID Reader
• ESP8266-12F Wi-Fi Module
• LM2596 Buck Converter
• Custom PCBs (EasyEDA)
• SolidWorks Enclosure Design

💻 Software

• Embedded C (SPI & UART protocols)
• React + Vite (Frontend)
• Express.js (Backend)
• PostgreSQL (Database)
• Node.js

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🚀 Functional Workflow

1. RFID reader (PN532) detects and reads nearby tags.
2. ATmega328P processes the UID and sends it to ESP8266 via UART.
3. ESP8266 transmits tag data to a remote PostgreSQL database.
4. Web app updates inventory and shipment statuses in real time.

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🧪 Field Testing

• Verified tag detection accuracy, Wi-Fi stability, and user workflows
• Refined enclosure and PCB based on field challenges (vibrations, range, alignment)

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👨‍💻 Contributors

• Udugamasooriya P.H.J.
• Perera A.L.C.K.
• Aazir M.A.M.
• Ranaweera R.P.D.D.H.
• De Alwis W.M.R.
• Walgampaya H.K.B.
• Vidmal S.S.A.A.
• Rathnayake R.M.T.N.B.

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📃 License

This project is licensed under the MIT License.

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