Development of a Line-Following Robot for Industrial Material Handling at the Nnewi Automotive Parts Manufacturing Cluster

The increasing demand for production efficiency in Nigeria's small-scale manufacturing sector has generated interest in low-cost automation solutions. This project focuses on the development of a line-following robot intended for material handling tasks within the Nnewi Automotive Parts Manufacturing Cluster in Anambra State, South East Nigeria. The robot uses an array of infrared sensors to detect a predefined track embedded on the factory floor and navigates autonomously between workstations, transporting lightweight components. An Arduino Uno microcontroller processes sensor signals and drives two DC gear motors through an L298N motor driver circuit. The mechanical frame was constructed from aluminium profiles to ensure durability under repeated loading conditions. Calibration tests were conducted to optimize sensor sensitivity and motor speed for smooth navigation around curves and intersections. The robot demonstrated reliable path-following performance during a simulated 48-hour continuous operation trial, with a position accuracy of plus or minus 15 millimetres. Economic analysis shows that the robot could reduce manual material movement time by approximately 45 percent in a single production shift. The study discusses design limitations including load capacity constraints and sensitivity to ambient light variation, and proposes improvements involving the addition of a load cell for weight monitoring and shielded sensor housings. This work demonstrates the practical application of mechatronics engineering principles to solve real industrial challenges in the Nigerian manufacturing context. Keywords: line-following robot, material handling, automation, Nnewi, industrial robotics