Design and Fabrication of Arduino based Color Sorting Machine

CHAPTER 1

INTRODUCTION

Nowadays, in the present state of intense competition, production efficiency is generally

regarded as the key of success. Production efficiency includes the speed at which production
equipment and production line can be lowering material and labor cost of the product,
improving quality and lowering rejects, minimizing downtime of production equipment and
low cost production equipment. In the cutting-edge-day scenario of competitive manufacturing
in commercial zone performance of manufacturing holds the important component for
achievement. It’s miles essential to beautify manufacturing pace, lower the labor charge and
reduce the breakdown time of production gadget. Machines can perform highly repetitive tasks
better than humans. Worker fatigue on assembly lines can result in reduced performance, and
cause challenges in maintaining product quality. An employee who has been performing an
inspection task over and over again may eventually fail to recognize the color of product.
Automating many of the tasks in the industries may help to improve the efficiency of
manufacturing system. Merchandise should be taken care of in numerous ranges of
manufacturing and manual sorting is time consuming and labor extensive.

1.1 Automation in sorting system

Automation is the use of control systems for handling different processes and machineries to
replace human efforts. Automated system uses a complicated algorithm which may be increase
the cost of the design. But this not only reduces manual efforts, time consumed, but gives more
time to work on factors like aesthetics. Using automation also prevents danger which might
occur when humans are made to work in hazardous environments. Thus, use of automation is
very useful in manufacturing industry. Automated sorting also decreased the labor cost and the
production time. The error cased due to human negligence is avoided by the use of automated
system by color-based sorting using a color sensor.

The Embedded Technology is now in its prime and wealth of knowledge available is mind-
blowing. An Embedded system was a special purpose computer system designed to perform a

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dedicated function. Embedded system is fast growing technology in various fields like
industrial automation, home appliances, automobiles, aeronautics etc. Embedded technology
uses pc or a controller to do the specified task and the programming was done using assembly
language programming or Embedded C. Industrial automation and robotics were at a high
demand in the industry as both of them directly affect the growth of the industry. Quality and
flexibility of the product was the important criteria of the industry. Use of industrial robots will
lead automation industry to another transition. Color based sorting was extensively used in
many industries for sorting purposes to ensure the quality of the object is up to the mark for
e.g. Food processing industries, pharmaceutical industries, automotive industries, agriculture
industries. Such sorting reduces the human effort, labor cost and also time of operation. Most
of the errors caused by humans were due to their limited potential which can be reduced by
using automated system supported by color based sorting. Despite, to provide good quality
products within the short time automated grading system is becoming popular among
manufacturing industries. This automated system is getting its priority due to its superior
speed, consistency and accuracy. The traditional visual quality inspection of manual sorting
and grading, which are performed by hired laborers is tedious, time-consuming, slow and
inconsistent and also it is difficult to hire the laborers who adequately trained and willing to
undertaken the tedious task. Therefore, this automated grading system in agriculture and
related industry will help to supply the increasing demand for high quality products as much as
quick at the same time it will have positive impacts on growth and development of that
particular industry. Thus, researches in this field will help to freeing the people from traditional
hand sorting and it will help to improve product quality. There are several approaches for
continuous recognition and sorting of objects according its outer parameter into desired
location. Industries today are approaching to use color sensor to full fill their needs for a higher
ruction and preside quality. Historically, components used for color sensing were considered
expensive and required precision support circuitry, limiting their application mostly to
specialized instrumentations. Color sensors with higher levels of integration are becoming
available, allowing for more cost effective solution. Determining real time and highly accurate
characteristics of small objects in a fast flowing stream would open new directions for
industrial sorting processes.

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1.2 Sorting

Sorting is any process of arranging items in some sequence and/or in different sets. It has two
common distinct meanings such as ordering and categorizing. Ordering is arranging items of
the same kind, class, nature, etc. in some ordered sequence while categorizing is grouping and
labeling items with similar properties together by sorts.

a) Sorting Information or Data

One important kind of sorting is arranging items of information in alphabetical sequence

according to some pre-defined ordering relation (sort key by each group of lists), e.g. when one
sorts the books in a library by title, subject or author (all alphabetically sorted normally in
ascending order). The resulting order may be either ascending or descending, because
essentially all sorting is numerical sorting. The main purpose of sorting information is to
optimize its usefulness for specific tasks.

b) Physical Sorting Processes

Various sorting tasks are essential in industrial processes. For example, during the extraction of
gold from ore, a device called a shaker table uses gravity, vibration, and flow to separate gold
from lighter materials in the ore (sorting by size and weight). Sorting is also a naturally
occurring process that results in the concentration of ore. Sorting results from the application of
some criterion or differential stressor to a mass to separate it into its components based on
some variable quality. Materials that are different, but only slightly such as the isotopes of
uranium, are very difficult to separate.

1.3 Color Sensing and Identification

Color sensor systems are increasingly being used in automated applications to detect
automation errors and monitor quality at the speed of production line. They are used in
assembly lines to identify and classify products by color. The objectives of their usage include
checking the quality of products, to facilitate sorting and packaging, to assess the equality of
products in storage, and to monitor waste products. Consequently, there is an abundance of
color sensors and the choice is often application-driven. Low cost and simple color sensors are

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preferred over sophisticated solutions for less demanding applications where the top priority is
cost and power consumption. Color names can be used and conjure reasonably consistent
perceptions. There have eleven basic color names that have been identified such as white, gray,
black, red, yellow, green, blue, orange, purple, pink, and brown. Most or all colors can be
described in terms of variations and combinations of these colors. Due to the fact that human
color vision is accomplished in part by three different types of cone cells in the retina, it
follows that three values are necessary and sufficient to define any color. Color theory
describes that there are three values that can be thought of as coordinates of a point in three-
dimensional space, giving rise to the concept of color space. Hue, saturation, luminance is one
such color co-ordinate system, or color space.

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CHAPTER 2

LITERATURE REVIEW

A deep literature review is conducted on design for sorting by using color identification sensor,
Arduino micro controller and stepper motor. Numerous approaches towards color sorting
machine are carried out and a survey is conducted to understand the features utilized in the
development of color sorting machine.

Most sensors are electrical or electronic, although other types exist. A sensor is type of
transducer. Sensors are either direct indicating (e.g. a mercury thermometer or electrical meter)
or are paired with an indicator (perhaps indirectly through an analog to digital converter, a
computer and a display) so that the value sensed becomes human readable. In addition to other
applications, sensors are heavily used in medicine, industry and robotics. A common
requirement in the field of color sensing is that of color identification, or sorting of objects by
color. Typically this type of application is simpler than a general-purpose color measurement
application. A common task in color sensing is to identify an unknown color as falling into one
of these general categories.

2.1 Color Identification

Color names can be used and conjure reasonably consistent perceptions. There have eleven
basic color names have been identified such as white, gray, black, red, yellow, green, blue,
orange, purple, pink, and brown. Most or all colors can be described in terms of variations and
combinations of these colors. Due to the fact that human color vision is accomplished in part
by three different types of cone cells in the retina, it follows that three values are necessary and
sufficient to define any color.

2.2 Color Theory

Berlien (2004) was said that there has three values can be thought of as coordinates of a point
in three-dimensional space, giving rise to the concept of color space. Hue, saturation,
luminance (HSL) is one such color coordinate system, or color space. A more precise method
of describing color is by hue, saturation, and lightness. Hue is the attribute of a color according

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to its similarity with one of the colors red, yellow, green, or blue, or a combination of adjacent
pairs of these colors considered in a closed ring, as shown in this figure 2.1.

Figure 2.1: HSL diagram with Hue circle (Berlien 2004)

2.3 Color and Light

A ‘color’ is an interaction between a very small range of electromagnetic waves and the eyes
and brain of a person. What people call red, green, or blue are just ways of categorizing what
their brain experiences. An article by Bishop and Lee (2006) brief that, the spectrum of light
where the eye can see is called the visible region as can be seen in figure 2.4. Light is a type of
energy, which makes up a small portion of the electromagnetic spectrum. Visible light could be
expressed as a frequency, but the magnitude is so large people generally express the
wavelength of light in units of nanometers (10-9 meters) to describe light. The region of visible
light consists of light with a wavelength between approximately 380 nm to 780 nm.

2.4 Color Sensor

Color sensors register items by contrast, true color, or translucent index. True color sensors are
based on one of the color models, most commonly the RGB model. A large percentage of the

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visible spectrum can be created using these three primary colors. Many color sensors are able
to detect more than one color for multiple color sorting applications. Depending on the
sophistication of the sensor, it can be programmed to recognize only one color, or multiple
color types or shades for sorting operations. Some types of color sensors do not recognize
colors, instead focusing on light wavelengths. Sensor can be configured to locate wavelengths
from near infrared (colors in the 750 nm to 2500 nm wavelength range), far infrared (colors in
the 6.00 to 15.00 micron wavelength range), and UV (colors in the 50 to 350 and 400 nm
wavelength range) in addition to the visible range. Sensors that read the visible range are the
most common type of color sensors. They measure color based on an RGB color model. A
large percentage of the visible spectrum (380 nm to 750 nm wavelength) can be created using
these three colors. Color sensors are generally used for two specific applications:

a) True color recognition

Sensors used for true color recognition are required to "see" different colors or to distinguish
between shades of a specific color. They can be used in either a sorting or matching mode. In
sorting mode, output is activated when the object to be identified is close to the set color. In
matching mode, output is activated when the object to be detected is identical (within
tolerance) to the color stored in memory.

b) Color mark detection.

Color mark detection sensors do not detect the color of the mark; rather they "see" differences
or changes in the mark in contrast with other marks or backgrounds. They are sometimes
referred to as contrast sensors. Color sensors shine light onto the object to be monitored and
measure either the direct reflection or the output into color components. Many color sensors
have integral light sources to achieve the desired effect. These integral light sources include
LEDs, lasers, fiber optic, and halogen lamps.

2.5 A review on color sorting system used in various industries and automation/type of
micro controller used in sorting, sensing the objects

Akriti Kaushik and Aastha Sharma defined that sensor or detector provides a way for gathering
data on generating operations and approaches being performed [1]. Accomplice degree

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enormously in a totally heap of instances sensors is want to transform a bodily input into an
electrical sign with a purpose to be analyzed by way of the manufacturing machine and used
for growing picks regarding the operations being performed. The purpose of sensors is to have
a look at upload development, to observe the paintings-in-progress aspect with the producing
utensils, and to allow self-monitoring of manufacturing of producing by means of the
manufacturing gadget’s personal pc. Color sensors check in stuff against this, real coloration,
or clear index. True color sensors are supported one in every of the Color models, maximum
usually the RGB version (pink, green, blue). An oversized share of the shade spectrum may be
created victimization those three primary colors. Several shade sensors are prepared to feel
quite one color for multiple color sorting packages.

Counting on the issue of the detector, it is able to be programmed to apprehend only one color,
or multiple shade kinds or sunglasses for categorization operations. Through this report, the
coloration detection, the essential shade concept and consequently, the packages of color
detector are evaluation. In the course of this document are that specialize within the appliance
of coloration detector victimization conveyor gadget Tushar G Gaikar et al., described that the
primary reason for the framework is to split the object as for his or her shading code a certainly
circulate the item as in keeping with their colors [2]. On this count, we can distinguish the
color of the object that is placed on shipping line you want and that question is dispatch to split
container. This could be done efficaciously via using headway as part of innovation in
particular in the discipline of inserted frameworks. Currently, a day's such a massive variety of
helpful improvements are turning out to make our manner of lifestyles extra solace,
extravagant and cosy. In this anticipate, we will be predisposed to utilize Arduino (controller)
and shading sensing detail. This shading sensing element distinguishes shading and offers
serial yield of RBG fee. It is going to distinguish 16.7 million shading sunglasses giving RBG
esteem for the diagnosed shading. The prominent shading is diagnosed as stay of three critical
shading values to be specific pink, inexperienced and blue with 8-bit accuracy for every crucial
shading. Any shading can be isolated or consolidated into three essential shades crimson, green
and blue making use of the RBG values.

Mingwei Liu explained that a robot which could comply with a black line on a white platform
[3]. This could be carried out via using eight photo resistors array. First, those sensors are set to

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be output. After delaying for a time period and placing ports enter again, this array will acquire
light from surroundings and transfers it into virtual signal. Since, black and white has
absolutely exclusive mirrored image regular, the automaton will use this to tell aside whether
or not or no longer it’s on a line or now not. The put off time is an essential parameter due to
the fact it could determine the sensitivity of the sensor. After experiment, numerous times we
discovered 200us is an appropriate put off time for my robot. Except chase the black line, the
automaton may even take a look at colors of an object. This could be completed by using a
distance IR sensing detail and an RGB color detection sensing element. The IR sensing
element will calculate the gap of partner degree obstacle in advance. The mechanism will
forestall at bound motive and use RGB coloration sensing detail to browse from it, IR sensing
element could be really used thru ADC Port. However, RGB coloration detector has got to use
twice conversation protocol to get shade because of the shade detector includes long way
greater information than IR sensing element. For actuation part, at the beginning, we used
equipment vehicles and a twin motor motive force to manipulate it. But, after converting the
platform of my robot, we found the vehicles had been not effective sufficient so, we changed
them with servos. The mechanism and patrol on the map, researching each habitual. Whilst it
detects item, it will distinguish whether or not or now not this item is crimson or blue. If the
road ends, it's going to turn around and move on. The vacation spot is a white place. The robot
can pass returned after going the vacation spot.

Abhishek Kondhare, Garima Singh, Neha Hiralkar and M S Vanjale explained that the venture
might be a terrific approach for a true time evaluation and desire of gadgets in continuous glide
[4]. Photo process in nowadays global grabs large attentions as it effects in potentialities of
broaden application in numerous fields of era. The $64000 challenge is the manner to improve
present sorting system inside the fashionable system gadget that includes four integrated
stations of identity, processing, choice and sorting with an alternative photo system function.
Present sorting method uses a collection of inductive, electrical phenomenon and optical
sensors that do differentiate item shade. This venture offers a mechatronics coloration sorting
machine answer with the equipment of picture process. Picture method manner senses the
items in an image captured in time period by way of a virtual camera and is classified using a
decisional formulation and hand-picked in real time. This information is processed image

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system for select-and-vicinity mechanism. This mission makes use of an automatic material
coping with system this is wide utilized in industries.

M Anil Kumar, Dr. S A K Jilani, Mr. U Sreenivasulu and Mr. S Javeed Hussain explained that
shade performs a vital function in human everyday lifestyles for reputation [5]. The maximum
objective is to develop a version which may additionally note absolutely different hues for
purblind people. They may be anticipated to have a hobby in the shade of their clothes, the
coloration of toys and additionally the shade of photos and so on. This technique allows the
purblind peoples to well known the colors at the same time as no longer the help of character,
in order that they may set up the colors severally.

Eagerness for automated image handling strategies come after two main application territories:
improvement of graphic data for individual perceptive; and preparing of image in order for
ability, broadcast, and portrayal for independent mechanism discernment. The goals of this
article are to characterize the significance and extent of picture preparing, examine the
different advances and systems associated with a common picture handling, and uses of picture
preparing devices and procedures in the outskirts territories of research [6]. It is about a visual
sorting setup in an industrial setting. They stated as to how items at random position can be
moved to the conveyer. Camera located above the conveyer locates the items. They assume
that there is a separator placed in front of the camera so that the incoming items do not overlap
[7].

An elevated‐speed, little‐cost, picture‐based arranging gadget are created to distinguish and

isolate grain with various hues/surfaces. The gadget straightforwardly joins a CMOS) shading
picture sensor with a field‐programmable door exhibit so as to customize to execute picture
handling. Spatial goals of the imaging framework are around 16 pixels/mm. Also, framework
uses innate parallel preparing capacities of FPGA's to assess three separate floods of grain with
a solitary camera/FPGA mix. Portions are pictured following dropping and finishing and are
redirected by enacting an air valve. Framework has rate of roughly 225 portions/s generally
speaking, that is a lot higher than recently created picture examination frameworks. Testing of
the framework brought about exactness’s of 96% for isolating red wheat from white wheat,
93% precision for isolating grain from durum, and 92% for isolating dark colored flax from

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yellow flax. Sorter should discover use in expelling different imperfections set up in grain, for
example, scab‐damaged as well as hit wheat. Part for the framework cost under $ 2,000 as a
result it might be efficient to dash a few frameworks in equivalent to stay aware of handling
plant rates [8].

Presently multi day's modern region requires interest for automation. Due to computerization
human endeavors are continues diminishing since a decade ago. The item arranging dependent
on shading is troublesome undertaking in ongoing days. In industry there is quickly expanding
requests for automation. The Sorting of articles dependent on shading is extremely troublesome
assignment. This task gives us a thought regarding programmed shading arranging. Here we
are structuring and executing a proficient shading arranging utilizing shading sensor TCS3200
dependent on Arduino UNO. This task gives high precision and execution. Existing arranging
technique utilizes a lot of inductive, capacitive and optical sensors do separate item shading
[9].

For arranging object in industry optical arranging is especially advantageous. Color and
dimension are mainly significant things to see for precise grouping and arranging of item
which should be possible by utilizing some optical sensors or breaking down their photos. The
shading arranging machine is predominantly a gadget that can detect the distinctive shade of
the item and declare them into various belt transport. At the point when object moves starting
with one spot then onto the next with the pivot of transport line, sensors as the information
gadgets send sign to microcontroller. The last outcome was very tasteful. The shading
identifying sensors functioned admirably and it had the option to distinguish red or green
article pleasantly and alter the course of servo on right and left side to sort the item in
legitimate spot. The belt moved from beginning stage to the end point through the roller
without clashing with the dividers. The framework performed well as customized and
recognizes the item as per their shading [10].

As a standard, self-decision robot can give convincing responses to tiring errands. For this
situation, it is alluring to make independent robot, recognizes objects from vehicle line and
move them if the article meets some criteria. Overseeing innumerable is particularly modest
task, which is a stunning application for a robot of this sort. For that circumstance, to keep plan

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multifaceted design low, robot is organized around the stage and uses a couple of interesting
sensors to accumulate information of robot’s condition to empower the robot to react in like
way. This paper goes for an issue that is trying to disclose & make an independent robot that
can perceive objects when put on vehicle line subject to shading identifying and after that sort
by relocating them to a specific territory. It will use an arm that uses a control motor to pick
particular thing from vehicle line and spot it as demonstrated by the shading distinguishing
method. Littler scale controller (AT89S52) licenses dynamic and speedier control. Liquid
Crystal Display (LCD) makes the system straightforward. AT89S52 Micro controller is the
center of the circuit as it controls all of the limits [11].

As tomatoes assumes fundamental job in our everyday life, arranging of tomatoes is vital in
assessing farming produce, satisfying quality guidelines and expanding market esteem. Human
power in farming area is generally utilized. In the event that the arranging and reviewing is
done through manual procedures, the procedure will be excessively moderate and now and
then it will be inclined to blunder. Shading is the most significant element for precise
arrangement and arranging of tomatoes. This exploration manages the plan and improvement
of a programmed tomato arranging machine dependent on a shading sensor. The machine
comprises of a transport framework, the arranging unit, a TCS34725 RGB shading sensor, and
an Arduino Uno board. The TCS34725 RGB shading sensor is utilized to identify the shade of
the tomato and the Arduino Uno, which is a PIC advancement board dependent on the
ATmega328 microcontroller, controls the general procedure. The tomatoes go in a straight line
on the transport to the arranging point. The recognizable proof of the shading depends on the
recurrence investigation of the yield of TCS34725 RGB shading sensor. In view of the
recurrence of the shading force caught by the sensor, the tomato would be arranged as ready or
unripe. The general framework exactness was 97.8%. Framework arranging execution was
evaluated at 2807 tomatoes for each hour with 1 line [12].

2.6 Problem Identification

In this present scenario, where there is a high challenge in modern assembling, the motivation
is to assemble different colored objects. Assembling has a fundamental significance. The
undertaking of automatic color arranging is incredible in view of its huge execution. Applying

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the possibility of the venture, the industries can sort the required item as indicated by its
shading. In spite of the fact that it has fewer impediments, however by doing few change this
idea of the project, it can be executed in wide scope of use. The principle points of interest of
the framework are that a smaller amount of time is required for sorting the items, as the entire
framework is performed by machine there is less plausibility of oversight, fewer labor required.
On and off chance is that any business can deliver the item inside the required range, at that
point the interest of the item will be expanded.

2.7 Objective

The main objective of the project is to sort the component according to color. The work is
considered to sort objects depending on its physical attributes such as outer stain color
intensity. To achieve the main objective, a prototype model will be built to sort the component
faster and efficient. The model will be built as a simple digital gadget like microcontroller for
processing, Servo motors for actions and coloration sensor for recognizing exclusive colored
objects.

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CHAPTER 3

METHODOLOGY

The present study follows the systematic methodology to design and develop the Colour
Sorting Machine using Arduino microcontroller. Fig. 3.1 shows the flow chart of methodology
conducted in the present study.

Extensive Literature survey

Problem Identification

Concept Development

System design, Materials and Methods

Development of Prototype

Testing and Validation

Conclusion

Figure 3.1: Flow chart of Methodology

1. Literature survey

An extensive literature survey is conducted to design and develop the automated colour sorting
machine. A deep study of colour theory, colour identification and colour sensor is carried out.
A detailed understanding of automated sensors and Arduino techniques are studied to design

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and develop the automated colour sorting machine. Researchers conducted various study on the
design of automated sorting machine are reviewed in detail.

2. Concept Development

According to the problem identified, the automated color sorting machine is best for color error
detection for sorting objects and plays a significant role in quality assurance and process
automation. Hence, the design, development and performance evaluation of the automated
color sorting machine is the suitable concept using an embedded system (Arduino based) to
serve as a time saving, low energy consuming and cost effective alternative for sorting and
grading for both industrial and commercial applications.

3. System Design, Material and Methods

Design requirements and consideration: The design of the embedded system will be structured
into three major parts namely, system design and its components from mechanical point of
view, implementation of microcontrollers and other electrical hardware and lastly the
command flow to achieve the machine automation. The design consideration is based on the
identified shortcomings of the manually operated sorting system. Subsequently, readily
available and low-cost materials are also considered in the design of the system. The design
requirement and consideration for the system are based on two control loops; the first is the
define-measure-analyze-control and second is the sensor system which combined with
downstream analysis software (arduino).

4. Prototype design

The proposed system will be designed for automatic color sorting machine. The prototype
consists of mechanical units, two servo motors, Arduino board and a color sensing circuit using
TCS3200.

5. Testing and validating with Sensors

For testing, different fruits with moderately circular shape and different colors will be used.
The tested result need to be evaluated to check the performance of the mechanism with
sensors.
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CHAPTER 4

CONCEPT DEVELOPMENT AND DETAIL DESIGN

4.1 Concept development

A conceptual model of Arduino based colour sorting machine is developed according to the
literature survey conducted. The conceptual model replicates the actual unit to be developed
for sorting different coloured objects. The device will be constructed to sort objects based on
the difference in the wavelength of the color. This will be made possible by the use of color
detection module, an open source operating system interfaced with an android remote
application and a mechanical system. The main concept of this machine deals with the
automation of the device centered on Arduino microcontroller prototype board. It is the control
unit of the entire system as it contains all the software design. Fig. 4.1 represents the schematic
diagram of conceptual model of Arduino based color sorting machine.

Top Servomotor TCS3200 Color Sensor

Sorted colored objects

Bottom Servomotor

Figure 4.1: Concept sketch of Arduino based colour sorting machine

The concept model shown in figure 4.1 comprises the mechanical parts such as conveyor belt
for feeding object one by one in a line, single feeding and sorting system and two outlets for
sorting into two categories. The detailed design of these mechanical parts are developed using
CAD tool.

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4.2 Detailed design of colour sorting system

To design and develop the colour sorting machine, the conceptual model is finalised and
considered for the development of 2D models using CAD tool such as SOLIDWORKS. The
detailed drawing of each unit is developed and utilized to develop 3D models. Fig. 4.2 to 4.5
represents the 2D model of each unit developed according to the conceptual model.

4.2.1 Conveyor design

The dimensions of conveyor are as shown in Fig. 4.2. The slope was kept to the repose angle to
minimize the product defects.

Figure 4.2: Dimensions of conveyor

4.2.3 Single feeding and sorting system

It was designed through two square boxes inner and outer square boxes as shown in fig. 4.3
and 4.4.

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Figure 4.3: upper and lower surfaces of outer square box

Figure 4.4: upper and lower surfaces of inner square box

4.2.4 Outlet design

In this system there are two outlets, which were designed as shown in fig. 4.5.

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Figure 4.5: parts of two outlets of the sorter

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CHAPTER 5

Fabrication of Arduino based Color Sorting machine

5.1 Fabrication of Color Sorting Machine

The color sorting machine developed in the form of 2D model is fabricated according to the
specifications followed in the 2D model. The required materials to fabricate the sorting system
is surveyed and outsourced to fabricate the unit. The color sorting system consists of 4 units
with Arduino based microcontroller.

5.1.1 Conveyor Belt System Requirements and Specifications

The system has two main conveyor belts: main belt to transport the object in one direction to
pass through the color sensor while the other sorting belt moves right and left to sort the
objects in two different categories or boxes. The process has control functions such as START
and STOP to help the users to manage the whole process even if the belt system is running.
The belts are speed managed and stopped if there is not item placed on it.

So the system has an obstacle sensor at the beginning of the main conveyor belt. Then the item
shall pass through the color sorting sensor. The Arduino decides the sorting belt direction
based on the color.

5.2 System design

The final system was automated using microcontroller (Arduino UNO), color sensor, DC
motor and a servo motor. The void setup and loop functions were fed up through Arduino
software. Based on color identified by the TCS2300 sensor the motor will turn to the left or
right. All the process is controlled by the Arduino UNO.

In this system commonly required the following components.

a) Arduino UNO
b) Servo Motors

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c) TCS230 Color Sensor

d) DC Motor
a) Arduino UNO R3

Arduino Uno is a microcontroller board based on the ATmega328P (datasheet). It has 14

digital input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, a 16 MHz
ceramic resonator (CSTCE16M0V53-R0), a USB connection, a power jack, an ICSP header
and a reset button. It contains everything needed to support the microcontroller; simply connect
it to a computer with a USB cable or power it with a AC-to-DC adapter or battery to get
started. The Uno differs from all preceding boards in that it does not use the FTDI USB-to-
serial driver chip. Instead, it features the Atmega16U2Atmega8U2 up to version R2)
programmed as a USB-to-serial converter. While the Arduino UNO can be powered via the
USB connection or with an external power supply, the power source is selected automatically.

External (non-USB) power can come either from an AC-to-DC adapter (wall-wart) or battery.
The adapter can be connected by plugging a 2.1mm centre-positive plug into the board's power
jack. Also leads from a battery can be inserted in the Gnd and Vin pin headers of the Power
connector. The board can operate on an external supply of 6 to 20 volts. If supplied with less
than 7V, however, the 5V pin may supply less than five volts and the board may be unstable. If
using more than 12V, the voltage regulator may overheat and damage the board. The
recommended range is 5v to 12v for Arduino Uno.

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Figure 5.1: Arduino UNO R3

Specifications:

Table 5.1 represents the specifications of Arduino UNO board.

Table 5.1: Specifications of Arduino UNO board

Model Type UNO Rev R3

Microcontroller Chip ATmega328P
Operating Voltage 5V
Input Voltage (Recommended) 7-12V
Input Voltage (limit) 6-20V
Analog I/O Pins 6
Digital I/O Pins 14 (of which 6 provide PWM output)
PWM Digital I/O Pins 6
DC Current per I/O Pin 20 mA
DC Current for 3.3V Pin 50 mA
Clock Speed 16 MHz
SRAM 2 KB (ATmega328P)
EEPROM 1 KB (ATmega328P)
32 KB (ATmega328P) of which 0.5 KB used by
Flash Memory
bootloader
On Board LEDs On/Off, L (PIN 13), TX, RX
Dimensions in mm (LxWxH) 68.6 x 53.4 x 12 mm
Weight 25 g

b) Servo Motors for Arduino

This High-Torque MG996R Digital Servo features metal gearing resulting in extra high 10kg
stalling torque in a tiny package. The MG996R is essentially an upgraded version of the
famous MG995 servo, and features upgraded shock-proofing and a redesigned PCB and IC
control system that make it much more accurate than its predecessor. The gearing and motor
have also been upgraded to improve dead bandwidth and centering. The unit comes complete
with 30cm wire and 3 pin 'S' type female header connector that fits most receivers, including
Futaba, JR, GWS, Cirrus, Blue Bird, Blue Arrow, Corona, Berg, Spektrum and Hitec. This
high-torque standard servo can rotate approximately 120 degrees (60 in each direction).

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Figure 5.2: MG996R Servo Motor

Specifications

 Weight: 55 g
 Dimension: 40.7 x 19.7 x 42.9 mm approx.
 Stall torque: 9.4 kgf.cm (4.8 V), 11 kgf.cm (6 V)
 Operating speed: 0.17 s/60º (4.8 V), 0.14 s/60º (6 V)
 Operating voltage: 4.8 V a 7.2 V
 Running Current 500 mA – 900 mA (6V)
 Stall Current 2.5 A (6V)
 Dead band width: 5 µs
 Stable and shock proof double ball bearing design
 Temperature range: 0 ºC – 55 ºC

Motor Control using Arduino:

Standard servo motor control using Arduino is extremely easy. This is because the Arduino
software comes with a sample servo sketch and servo library that will get you up and running
quickly firstly, connect the black wire from the servo to the GND pin on the Arduino and
connect the red wire from the servo to the +5V pin on the Arduino and then the third wire
(usually orange or yellow) from the servo is connected to a digital pin on the Arduino.

c) TCS230 Color Sensor

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The TCS3200 programmable color light-to-frequency converters combine configurable silicon

photodiodes and a current-to-frequency converter on a single monolithic CMOS integrated
circuit. The output is a square wave (50% duty cycle) with frequency directly proportional to
light intensity (irradiance). The full-scale output frequency can be scaled by one of three preset
values via two control input pins. Digital inputs and digital output allow direct interface to a
microcontroller or other logic circuitry. Output enable (OE) places the output in the high-
impedance state for multiple-unit sharing of a microcontroller input line.

In the TCS3200, the light-to-frequency converter reads an 8 x 8 array of photodiodes. Sixteen

photodiodes have blue filters, 16 photodiodes have green filters, 16 photodiodes have red
filters, and 16 photodiodes are clear with no filters. The four types (colors) of photodiodes are
interdigitated to minimize the effect of non-uniformity of incident irradiance. All photodiodes
of the same color are connected in parallel. Pins S2 and S3 are used to select which group of
photodiodes (red, green, blue, clear) are active. Photodiodes are 110 μm x 110 μm in size and
are on 134-μm centers.

Figure 5.3: TCS230 Color Sensor

TCS230 Color Sensor is used with this color sorting machine. This sensor acts as a perfect
color sensor for the color sorting Machine. The TCS230 Color sensor’s PCB module includes a
TAOS TCS230RGB color sensor chip, white LEDs (4 Numbers) and LED control circuit with
some basic components. Features of TCS230 Color Sensor are a programmable high resolution
color light to frequency converter sensor. It provides a programmable color and full scale
output frequency and can directly control with the Microcontroller.

In this color sorter, it is essential need to know about Infrared Object Detection Sensor. This
Medium Range Infrared sensor offers simple, user friendly and fast obstacle detection using

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infrared; it is non-contact detection. The implementations of modulated IR signal immune the

sensor to the interferences caused by the normal light of a light bulb or the sun light. The
sensing distance can be adjusted manually.

d) DC motor

DC Motor – 10RPM – 12Volts geared motors are generally a simple DC motor with a gearbox
attached to it. This can be used in all-terrain robots and variety of robotic applications. These
motors have a 3 mm threaded drill hole in the middle of the shaft thus making it simple to
connect it to the wheels or any other mechanical assembly. The most popular L298N H-bridge
module with onboard voltage regulator motor driver can be used with this motor that has a
voltage of between 5 and 35V DC.

Figure 5.4: DC motor

Specifications

 RPM: 10.

 Operating Voltage: 12V DC

 Gearbox: Attached Plastic (spur)Gearbox

 Shaft diameter: 6mm with internal hole

 Torque: 7 kg-cm

 No-load current = 60 mA(Max)

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 Load current = 300 mA(Max)

5.3 Performance test of system components

The performance of each component was first tested by connecting them to a circuit
individually. This ensures each of them functions properly. All components are then connected
to test the circuit of the entire system. This is done to ensure that the system is consistent and
that no connections are broken. To evaluate the system's sorting capability, red and yellow
objects are fed into the conveyor belt. Figure 5.5 shows the circuit diagram of system.

Figure 5.5: Circuit diagram of automation system

5.4 Operation of System design with conveyor belt

The system is based on an Arduino UNO microcontroller connected to an Ultrasonic distance

sensor to detect the presence of the object at the start point. Another infrared (IR) sensor is
located next to the color sensor at the middle point of the Main Conveyor Belt. Whenever an
object reaches the IR sensor, the Main belt stops and the color sensor detects the color of the
object.

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The Arduino receives the color sensor's data and analyze it. Based on those data, the Arduino
can recognize if the object is Red or Yellow. Then the Arduino controls the movement of the
sorting belt (clockwise or counterclockwise) to sort the object based on its color.

a) If the START button is pressed, the system is ready to receive an object.

b) if an item is placed on main belt in front of the ultrasonic sensor, the main belt moves
forward.
c) When the object reaches the object presence sensor, the main belt stops and the color
sensors feeds the controller with the color of the item.
d) The main belt moves forward to transport the item to the sorting belt that moves either
to the right or to the left based on the color of the item.
e) The system stops after a period of time unless another item is placed.
f) If the stop button is pressed, the system shall stop after the current sorting process and
shall not run even if an item is placed on the main belt.
g) The speed is controlled by the variable resistor regardless of the color, size, or weight
of the item.

Figure 5.6 shows the block diagram of operation of system.

Figure 5.6: Block diagram of operation of system

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CHAPTER 6

RESULT AND DISCUSSION

This system has been developed as a sorting machine using Arduino for automatic color
sorting, taking into consideration two colors namely yellow and Red. So the results are shown
as the following figures step by step involved in the process. To test the color detection and
sorting of objects, lemon and tomato are considered in this project.

Firstly, the object will be sensed by the infrared detection object sensor as the object moves on
the conveyor belt. At the second stage, it senses the object color by TCS2300 color sensor. In
this stage, when the object (lemon or tomato) reached under the sensor, the sensor starts
reading it. Upon sensing the color of object, the servo motor rotates to the specific positions for
each color as programmed in the Arduino. Figure 6.1 shows the detailed result of sorting
objects according to the color sensed by the TCS2300 color sensor.

Figure 6.1: Sorting objects according to the color sensed by the TCS2300 color sensor

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CHAPTER 7

CONCLUSION

In today's highly competitive industrial production environment, maintaining the integrity of a

product's supply chain from raw material to finished product through quality manufacturing is
critical. The bearing of high quality and dimensional precision is required for the declaration of
a product. As a result, because of its working concept and vast use, this automatic color sorting
project is a great one. An industry can quickly sort the required product based on its coloration
by implementing the project's concept. This concept can be used in a variety of applications.

FUTURE WORK

It is very useful in wide varieties of industries along with the help of PLC and SCADA,
especially in the packaging section. Automatic sorting machine enhances efficiency,
practicality, and safety of operators. It ensures remarkable processing capacity as well as
peerless performance including color detection. Of course we need to add high speed DC
motors and sensors with appreciable response to speed up the system for industrial application.

The model can be improved by making some changes in the program and components. Some
suggestions are given below.

a) A load cell can be added to measure and control the weight of the product.
b) Counter can be added to count the number of products.
c) Speed of the system can be increased accounting to the speed of production.
d) The system can be used as a quality controller by adding more sensors.
e) The sensor can be changed according to the type of product.
f) The DC motor can be replaced with stepper motor.
g) The PIC can be replaced with PLC.

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REFERENCES

[1] Akriti Kaushik, Aastha Sharma (September 2013), “RGb Color Sensing Technique",
International Journal Of Advance Research In Science And Engineering, IJARSE, Volume 2,
Issue 9, ISSN-2319- 8354(E), Available from http://www.ijarse.com.

[2] Tushar G Gaikar, Soham N Zadokar, Rajendra S Bhandari, Sagar S Patil, “Object Sorting
using Color Sensor and Arduino”, International Journal on Recent and Innovation Trends in
Computing and Communication, Volume 4, Issue 4, pp. 483−486, ISSN:2321-8169.

[3] Mingwei Liu, “EEL5666 Intelligent Machine Design Lab” Available from
https://mil.ufl.edu/5666/papers/IMDL_ Report_S pring_11/Final%20Reports/Mingwei_
Liu/Mingw ei_Liu.pdf.

[4] Abhishek Kondhare, Garima Singh, Neha Hiralkar, MS Vanjale (2014), “Color and Shape
Based Object Sorting”, International Journal Of Scientific Research And Education, Volume 2,
Issue 3, pp. 553−562, SS (e):2321-7545.

[5] M Anil Kumar, Dr. SAK Jilani, Mr. U Sreenivasulu, Mr. S Javeed Hussain (August 2015),
“Automated Color Recognition System for Visually Challenged and Achromatopsia People
using Arduino and Mobile App", International Journal of Advanced Research in Electronics
and Communication Engineering (IJARECE), Volume 4, Issue 8, ISSN: 2278–909X.

[6] T. Pearson, “Sorting of grains by color and surface texture”, 2009.

[7] H. Isil Bozma, H - ulyaYal. cin, “Visual processing and classification of items: a selective
perception approach”;2002.

[8] Mr. Umesh A. Chatte, “Arduino based object sorting”, March 2018.

[9] Sattom Halder, Md. Kamrul Islam, Mahmood Sabria Chowdhury and S. C. Banik:
“Development of an automatic color sorting machine on belt conveyer”; May 2014.

[10] Dharmannagari Vinay Kumar Reddy, “Sorting of objects on color by picking and place
robotic arm and with conveyor belt arrangement”; January 2014.

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[11] Vikas Chakole, Pranay Ilamkar, Rupesh Gajbhiye, SuhasNagrale, “Oranges sorting using
Arduino microcontroller”; February 2019.

[12] Abdullahi Ahmad ADAMU, Aduma Shehu, “Development of an Automatic Tomato

Sorting Machine Based on Color Sensor”; 2018.

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APPENDIX

// Libraries:

#include <Servo.h> //Built-In Library

// Pin Numbers:

#define S0 4

#define S1 5

#define S2 6

#define S3 7

#define sensorOut 8

#define Servo_Pin 9

#define Motor_Pin 10

// Objects:

Servo objServo;

// Variables:

int srvTomatoPos = 40;

int srvLemonPos = 85;

// Stores frequency read by the photodiodes

int redFrequency = 0; //120-280

int greenFrequency = 0; //180-450

int blueFrequency = 0; //130-350

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// Replace with values which are read from calib prgrm.

int redFrqLow = 100;

int redFrqHigh = 300;

int greenFrqLow = 160;

int greenFrqHigh = 480;

int blueFrqLow = 110;

int blueFrqHigh = 380;

// Stores the red. green and blue colors

int redColor = 0;

int greenColor = 0;

int blueColor = 0;

void setup() {

pinMode(S0, OUTPUT);

pinMode(S1, OUTPUT);

pinMode(S2, OUTPUT);

pinMode(S3, OUTPUT);

// Setting the sensorOut as an input

pinMode(sensorOut, INPUT);

// Setting frequency scaling to 20%

digitalWrite(S0, HIGH);

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digitalWrite(S1, LOW);

// Begins serial communication

Serial.begin(9600);

objServo.attach(Servo_Pin);

objServo.write(srvTomatoPos);

pinMode(Motor_Pin, OUTPUT);

digitalWrite(Motor_Pin, HIGH);

void loop() {

readColor();

void readColor() {

// Setting RED (R) filtered photodiodes to be read

digitalWrite(S2, LOW);

digitalWrite(S3, LOW);

// Reading the output frequency

redFrequency = pulseIn(sensorOut, LOW);

redColor = map(redFrequency, redFrqLow, redFrqHigh, 255, 0);

// Printing the RED (R) value

Serial.print("R = ");

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Serial.print(redColor);

delay(100);

// Setting GREEN (G) filtered photodiodes to be read

digitalWrite(S2, HIGH);

digitalWrite(S3, HIGH);

// Reading the output frequency

greenFrequency = pulseIn(sensorOut, LOW);

greenColor = map(greenFrequency, greenFrqLow, greenFrqHigh, 255, 0);

// Printing the GREEN (G) value

Serial.print(" G = ");

Serial.print(greenColor);

delay(100);

// Setting BLUE (B) filtered photodiodes to be read

digitalWrite(S2, LOW);

digitalWrite(S3, HIGH);

// Reading the output frequency

blueFrequency = pulseIn(sensorOut, LOW);

blueColor = map(blueFrequency, blueFrqLow, blueFrqHigh, 255, 0);

// Printing the BLUE (B) value

Serial.print(" B = ");

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Serial.print(blueColor);

delay(100);

if (redColor < -500 && greenColor < -500 && blueColor < -500) {

Serial.println(" - Empty");

} else if (redColor > -100 && redColor > greenColor+100 && redColor > blueColor+100) {

Serial.println(" - RED");

objServo.write(srvTomatoPos);

delay(1000);

} else if (redColor > 50 && greenColor > 50 && blueColor > -300) {

Serial.println(" - YELLOW");

objServo.write(srvLemonPos);

delay(1000);

} else {

Serial.println(" - OTHERS");

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