Automation
Automation
(JIAE)
Vol. 2, No. 2, September 2022: 147-157
http://asasijournal.id/index.php/jiae
http://doi.org/10.51662/jiae.v2i2.87
Abstract Keywords:
Object sorting is a basic process that is employed in a variety of disciplines in our Arduino Mega:
daily lives for our convenience. Previously, the sorting operation was done by hand Collecting Box;
using labor justification. Because product quality does not remain consistent during Conveyor;
the typical sorting process, it adds complexity to the segregation of products based on DC motor;
their height, color, size, and weight. This method is also time-consuming and slows Load Cell;
down output. To overcome these problems, Low-Cost Automation (LCA) has been Servo motors;
implemented in the sorting system, which aims to reduce production time, labor cost,
and processing complexity, improve product quality, increase production rate, etc. So, Article History:
in this project, an effective method has been developed for automatically sorting the Received: September 4, 2022
object based on color and weight. This method uses a conveyor belt, strain gauge load Revised: September 16, 2022
cell, DC motor, servo motor, TCS 34725 RGB color sensor, LCD, LED, and LDR to Accepted: September 20, 2022
identify, separate, and collect the objects according to their color and weight. Arduino Published: September 25, 2022
is used to controlling all the processes. This work has sorted three types of colors -red,
, green, and blue, and the weight of different ranges. Firstly, the weights have been Corresponding Author:
sorted by load cell, and then the desired colors have been sorted by color sensor. A Tasnuva Jahan Nuva,
bucket at the end of the conveyor belt can be rotated depending on the signal sent from Department of Mechatronics
the Arduino to collect the box. The collecting box has a specific portion in a particular and Industrial
color. Hence, it could be rotated at a specific angle for an exact weight for red, blue, Engineering.CUET.
and green colors. Bangladesh
Email:
This is an open access article under the CC BY-SA license [email protected]
INTRODUCTION
The shift of an economy from one that is primarily agricultural to one that is reliant on
product manufacture is known as industrialization. Individual manual work is regularly
displaced by mechanized industrial manufacture, and assembly lines frequently replace
craftsmen. Economic development, more productive separation of labor, and the usage of
technical advancement to address challenges are both characteristics of industrialization
compared to reliance on conditions outside human influence [1]. Industrialization plays a
vital role in the economic growth of any underdeveloped country. From the previous record,
developed countries broke their poverty by creating industrialization rather than
concentrating on agriculture or natural resources.
Nowadays, automation plays a vital role in making industrial operations more efficient
and flexible. The use of control systems, such as computers or robots, and information
technology for handling various processes and machinery in an industry to replace a human
being is known as industrial automation. It is the next step in the industrialization process
after mechanization [2]. Automation includes maximum production rates, raised
productivity, improved worker safety, reduced production time, and excellent product
quality. Enhanced productivity and maximum output are the two biggest causes of using
automation.
T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on … 147
Journal of Integrated and Advanced Engineering (JIAE)
Vol. 2, No. 2, September 2022: 147-157
The manufacturing industry has some products with little differentiation in color, weight,
size, height, and shape. For this, sorting plays a vital role in any production system.
Previously, sorting was done manually by labor, but it is a very difficult and time-
consuming system. To address these issues, an automated sorting system was created.
However, the economy is an important element in the development of every sector. As a
result, Low-Cost Automation (LCA) must be improved in order to sort the pieces efficiently.
Therefore, the Low-Cost Automation System (LCA) has been developed in this project for
sorting objects by color and weight [3].
The objectives of this system are: to design a system that can sort the objects according to
their color and weight, to fabricate the system for simultaneous sorting, to collect the objects
according to their color and weight into the collecting box, and to find the object sorting
precision and accuracy based on color and weight. Some scopes while designing this system
are: in the food processing industry too, sorting and packaging the products, scaling and
classification of agricultural goods, pharmaceutical businesses, assembling the same color
products in one packing box, and where risky and repeated works are performed.
148 T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on …
p-ISSN: 2774-602X e-ISSN: 2774-6038
Jyothi et al. [11] improved a project about separating objects based on color and size on a
conveyor belt. Here they used Arduino Uno and wireless monitoring system. Bargal et al.
[12] have developed a project about PLC based object sorting system. They have built an
LCA system for sorting lightweight items based on height variation, which is operated by
DC geared motors. The object is passed in front of sensors by the Programmable Logic
Controller (PLC) and the conveyor in the device, and sorting logic is determined. Yadav et
al. [13] have invented a project about color sorting system based on IoT. Arduino, dc
motors, and a mechanical arm are used here for controlling the robotic arm, which separates
objects according to color. The outcome of this project can be stored on the cloud
Thingspeak. Adebimpe et al. [14] discovered a system that can identify objects according to
color. A robotic arm used to sort objects. Yang et al. [15] published a paper about sorting
systems according to height on a conveyor belt using PLC. Also used photo electric sensor.
Sasidhar et al [16] presented the Color Sorting Machine is controlled by a Programmable
Logic Control (PLC) and SCADA-based control system. Dezaki et al. [17] designed A
pneumatic conveyor robot for color detection and sorting. This project aims to design and
construct an automated and intelligent mechatronic conveyor system for carrying and
positioning circular products in the manufacturing and packaging industries.
Vandana et al. [18] have developed an S71200-PLC-based sorting system according to
the color of the objects. They used a TCS2300 Color sensor, electromagnetic actuators and a
conveyor belt. Patunkar et al. [19] have designed PLC based sorting system for height, and
weight. They also used a Color sensor, a Pneumatic actuator, and, a Conveyor belt. Dunakhe
et al. [20] developed PLC-based color sorting system in the Conveyor belt. They used
Image processing algorithms to sort objects according to parameters. Ananthi et al. [21]
designed and fabricated color based automatic yarn carrier sorting machine. The Pneumatic
cylinder has used to transfer yarn in their respective place. Raj [22] et al. have advanced
Ardino-based product sorting systems according to size. The system consists of a proximity
sensor, pneumatic actuator, IR sensor, and conveyor belt. Another work we have done on
color sorting using color sensor and something like that [23].
Kumbhar et al. [24] proposed a system where weight is used as a sorting criterion in this
paper's proposed sorting algorithm. The constructed machine tries to use mechanical and
electronic components in conjunction with one another. The load cell arrangement takes
center stage in the system. Kannaki et al. [25] developed a system for design, construction,
assembly, and commissioning of an automatic Sorting machine using a Weighing
mechanism are presented in this work. Weighing scales or weighing machines are the most
common methods of measurement. Weighing machines are measuring instruments used to
determine an object's weight or mass. Anekar et al. [26] have proposed an effective method
for identifying and distinguishing items based on their weight and color using a load cell,
inductive sensor, and TCS 230 color sensor. A microcontroller is used to power the device.
The sorting of items as a whole is used. Objects that do not meet the system's requirements
are rejected and discarded by a pneumatic cylinder moving them out of the conveyor line.
Prasad et al [27] developed an automatic sorting machine prototype uses a pneumatic
system to allow systematic sorting of carton boxes according to their sizes, which is
accomplished using pneumatic cylinders and direction control valves. Ali et al. [28] have
developed an LCA system for multi-machine operation and sorting light weight objects
based on height variation using DC geared motors, induction motors, and stepper motors
that are controlled by a PLC, Variable Frequency Drive (VFD), and the conveyor in the
system passes the object in front of sensors and thus sorting logic is decided.
T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on … 149
Journal of Integrated and Advanced Engineering (JIAE)
Vol. 2, No. 2, September 2022: 147-157
Aruna et al. [29] invented an Automatic conveyor System with In–Process Sorting
Mechanism using PLC and HMI System. Many businesses use the same conveyor belt to
transport task parts of varied sizes, which must be separated at various points along the
manufacturing line. They are employing an automated procedure to separate materials of
various sizes for this purpose. Yadav et al. [30] improved an LCA (Low-Cost Automation)
system that has been devised to categorize things according to their height. The PLC is in
charge of this LCA system (PLC). This project is divided into two sections. The first is
software that comprises ladder logic programming and is used to program a PLC that
controls the entire project's operation. The second component is the hardware, which
includes conveyors for transporting the articles and sensors for detecting their height.
Method
In this project, the conveyor belt was initially designed in Fusion 360 software. Then, it
was made by frame, roller, pillow block, motor and belt. On the front side of the conveyor
belt, the load cell and servo mechanism were mounted, and at the end of the conveyor belt,
there is a collecting box with a red, blue and green portion for collecting objects. All of the
hardware equipment was attached above the conveyor belt. Arduino has controlled the
whole system. Power supply has been given through the adapter for activating the sorting
system. And then, a full color and weight-based sorting were obtained. The process is shown
in Figure 1.
150 T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on …
p-ISSN: 2774-602X e-ISSN: 2774-6038
Figure 4. Components above the conveyor belt Figure 5. Servo mechanism and Load cell
Figure 6. Adjusted all components above the Figure 7. Adjusted Collecting Box
conveyor belt.
T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on … 151
Journal of Integrated and Advanced Engineering (JIAE)
Vol. 2, No. 2, September 2022: 147-157
152 T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on …
p-ISSN: 2774-602X e-ISSN: 2774-6038
Figure 11. LCD Display Figure 12. Pushed out the product out of the range of
weight 100-250gm
Figure 13. Color and weight sorting for Red color Figure 14. Color and weight sorting for no color
object object
T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on … 153
Journal of Integrated and Advanced Engineering (JIAE)
Vol. 2, No. 2, September 2022: 147-157
Figure 15. Objects are in the collecting box in their respective portion
154 T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on …
p-ISSN: 2774-602X e-ISSN: 2774-6038
CONCLUSION
Industrial manufacturing procedures are becoming more competitive and complex these
days. With high quality and precision, supply product management, from raw material to
final product, is a critical component of any manufacturing process. As a result, any large-
scale industry that performs mass production would benefit from an automatic color and
weight sorting system. This project will boost production rate, repeatability, labor cost
reduction, error reduction, and labor material handling time. This sorting system will
automatically separate things based on their weight and color and package the products. The
sorting system comprises mechanical and electrical components like an Arduino, a load cell,
sensors, a conveyor belt, a collecting box, and motors, among other things. This sorting
system will save money and be simple in any industry. Finally, this sorting method will be
critical in industries and a country's economic progress.
ACKNOWLEDGMENT
The authors would like to express their gratitude to the Mechanical Engineering and
Mechatronics and Industrial Engineering departments at Chittagong University of
Engineering & Technology for their technological assistance. We would like to convey our
T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on … 155
Journal of Integrated and Advanced Engineering (JIAE)
Vol. 2, No. 2, September 2022: 147-157
heartfelt gratitude to all of our family members, friends, and anyone who assisted us in any
way during the project's development. Finally, I want to express my gratitude to the
Almighty for all that He has made possible.
REFERENCES
[1] NN, What is the relationship between industrial revolution, industrialization and industrial relations? –
Quora, https://www.quora.com/What-is-the-relationship-between-industrial-revolution-industrialization-
and-industrial-relations (accessed Sep. 10, 2019)
[2] NN, What is Industrial Automation? - Sure Controls, https://www.surecontrols.com/what-is-industrial-
automation/ (accessed Apr. 26, 2022)
[3] A. K. Singh and M. S. R. Ali, “Automatic sorting of object by their colour and dimension with speed or
process control of induction motor,” 2017 International Conference on Circuit ,Power and Computing
Technologies (ICCPCT), 2017, doi: 10.1109/ICCPCT.2017.8074289
[4] A. Thike, Z. Z. Moe San, and D. Z. Min Oo, “Design and Development of an Automatic Color Sorting
Machine on Belt Conveyor,” International Journal of Scientific Engineering and Applied Science,” vol.
8, no. 7, pp. 176–179, Jul. 2019, doi: 10.7753/ijsea0807.1002
[5] C. K. Kunhimohammed, M. S. K. K, S. Sahna, M. S. Gokul, and S. U. Abdulla, “Automatic Color
Sorting Machine Using TCS230 Color Sensor And PIC Microcontroller,” International Journal of
Research and Innovations in Science and Technology, vol. 2, no. 2, pp. 33–38, 2015
[6] H. G. Rudresh, P. S. P, and A. I. T. Ie, “Colour Sensor Based Object Sorting Robot,” International
Research Journal of Engineering and Technology (IRJET), vol. 4, no. 8, pp. 504–507, 2017
[7] H. Patel and R. Joy, “IOT Color Based Object Sorting Machine,” International Journal of Applied
Engineering Research, vol. 13, no. 10, pp. 7383–7387, 2018.
[8] L. Fernandes and B. R. Shivakumar, “Identification and Sorting of Objects based on Shape and Colour
using robotic arm,” Proc. 4th Int. Conf. Inven. Syst. Control. ICISC 2020, February, pp. 866–871, 2020,
doi: 10.1109/ICISC47916.2020.9171196.
[9] A. Amhani and Z. Iqbal, “Automated color sensor system using LDR and RGB leds controlled by
Arduino,” ARPN Journal of Engineering and Applied Sciences, vol. 12, no. 19, pp. 5532–5537, 2017.
[10] P. S. Bhaskar, “Colour Sorting System with Robotic Arm,” International Journal for Innovative
Research in Science & Technology, vol. 2, no. 10, pp. 267–272, 2016.
[11] H. S. Jyothi and B. K. Harsha, “Design A Conveyor Based on Size and Color Separation of Product
Using Arduino Uno Microcontroller,” International Journal of Creative Research Thoughts (IJCRT), vol.
5, no. 4, pp. 2532–2539, 2017
[12] P. N. Bargal, A. Deshpande, R. Kulkarni, and R. Moghe, “PLC Based Object Sorting Automation,”
International Research Journal of Engineering and Technology (IRJET), pp. 103–108, 2016
[13] A. Yadav, A. Zanzane, S. Soni, S. Teli, and P. Kamble, “Color Based Product Sorting Machine Using
PLC,” SSRN Electronic Journal, vol. 4, no. 3, pp. 25–29, 2019, doi: 10.2139/ssrn.3372980
[14] A. M. Adebimpe, D. C. Uguru-Okorie and E. O. Oluwagunwa, “Design and Production of an Automatic
Solid Waste Sorting Machine with Smart Digital Counter,’ Nigerian Journal of Technology, vol. 41, no.
3, pp. 542-546, 2022, doi: 10.4314/njt.v41i3.14
[15] H. Yang, G. Hu and L. Lu, "Research on an Automatic Sorting System Based on Machine Vision," 2022
International Seminar on Computer Science and Engineering Technology (SCSET), 2022, pp. 27-31, doi:
10.1109/SCSET55041.2022.00016
[16] K. Sasidhar, S. Farooqi, M. A. Moin, and M. Sachin, “Design and Development of a Colour Sorting
Machine using PLC and SCADA,” International Journal of Research and Scientific Innovation (IJRSI),
vol. 5, no. 7, pp. 198–202, 2018
[17] M. L. Dezaki, S. Hatami, A. Zolfagharian, and M. Bodaghi, “A pneumatic conveyor robot for color
detection and sorting,” Cognitive Robotics, vol. 2, no. March, pp. 60–72, 2022, doi:
10.1016/j.cogr.2022.03.001
[18] S. Vandana, K. Shamukha Sri Sai, P. Rohila, and V. Manideep, “PLC Operated Colour Based Product
Sorting machine,” IOP Conference Series: Materials Science and Engineering, vol. 1119, no. 1, p.
012016, 2021, doi: 10.1088/1757-899x/1119/1/012016
[19] P. A. S. Y. T. R. K. M. Prashant Patunkar, “Design and Development of Product Sorting Conveyor Belt
using PLC,” International Research Journal of Engineering and Technology (IRJET), vol. 8, no. 6, pp.
4337–4340, 2021
[20] A. Dunakhe, P. Sakhe, A, Sangale and A. Dakre, “PLC based Color Sorting Conveyor System,”
International Journal of Engineering Research in Electronics and Communication Engineering
156 T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on …
p-ISSN: 2774-602X e-ISSN: 2774-6038
T. J. Nuva et al., Design & Fabrication of Automatic Color & Weight-Based Sorting System on … 157