CHAPTER 1

INTRODUCTION

Nowadays, most people believe that production efficiency is the key to success in the current
environment of fierce competition. The speed at which production lines and equipment can
reduce labor and material costs for the product, improve quality and reduce rejects, and
minimize downtime of low-cost manufacturing equipment are all examples of production
efficiency. In today's competitive manufacturing environment in commercial zones, production
performance is a critical factor in success. Enhancing manufacturing speed, reducing labor
costs, and decreasing production device breakdown times are all crucial. Highly repetitious
jobs are better performed by machines than by people. On assembly lines, worker fatigue can
lead to decreased productivity and make it more difficult to maintain 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 process of replacing human labor by using control systems to manage
various machinery and processes. A complex algorithm used by automated systems may raise
the design's cost. However, this not only saves time and hard labor, but it also frees up more
time to work on aspects like appearance. Additionally, automation eliminates the risk that
could arise from placing people in dangerous jobs. Automation is therefore tremendously
helpful in the manufacturing sector. Additionally, automated sorting reduced manufacturing
time and personnel costs. The adoption of an automated system with color-based sorting
utilizing a color sensor prevents errors caused by human ignorance.

Now that embedded technology is at its peak, there is an incredible amount of knowledge
available. A special purpose computer system created to carry out a specific task was known as
an embedded system. In a variety of industries, including industrial automation, home
appliances, vehicles, and aviation, embedded systems are a rapidly expanding technology.
Computers or controllers are used in embedded technology to carry out predetermined tasks,
and Embedded C or assembly language programming were used for programming . Due to their
direct impact on the industry's growth, industrial automation and robots were highly sought
after. The industry's key criterion was product quality and adaptability. Automation will
undergo another change as a result of the use of industrial robots. In order to guarantee that the
quality of the product is up to par, color-based sorting has been widely employed in a variety
of industries, including the food processing, pharmaceutical, automotive, and agricultural
sectors. Such sorting lowers operating time, labor costs, and human effort. The majority of
human errors were caused by their restricted capabilities, which can be lessened by employing
automated systems that use 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 various methods for continuously identifying and
classifying objects based on their external parameters in the intended area. Color sensors are
being used by industries nowadays to fully satisfy their demands for improved performance
and quality. The use of color sensing components was formerly restricted to specialized
instrumentation due to their high cost and requirement for precise support circuitry. More
affordable solutions are now possible because to the development of color sensors with greater
degrees of integration. Industrial sorting procedures could take new turns if it were possible to
identify the precise and real-time features of tiny items in a swiftly moving stream.
1.2 Sorting

Sorting is the process of putting things in distinct sets or in a certain order. It can be interpreted
in two different ways, such as categorizing and arranging. While classifying is grouping and
labeling items with similar properties together by sorts, ordering entails placing items of the
same kind, class, nature, etc. in some ordered sequence.

a) Sorting Information or Data

Sorting information in alphabetical order based on a predetermined ordering relation (sort key
by each group of lists) is a significant type of sorting. For example, when books in a library are
arranged alphabetically by title, subject, or author, they are all arranged generally in ascending
order. Since practically all sorting is numerical sorting, the final order could be either
ascending or descending. Sorting information is mostly done to maximize its utility for
particular purposes..

b) Physical Sorting Processes

In industrial processes, a variety of sorting activities are crucial. In order to separate gold from
lighter components in the ore (sorting by size and weight), for instance, a machine known as a
shaker table uses gravity, vibration, and flow. Another naturally occurring process that leads to
mineral concentration is sorting. Sorting is the process of applying a criterion or differential
stressor to a mass in order to divide it into its constituent parts according to a variable quality.
Separating materials that are only marginally different, like uranium isotopes, is extremely
challenging.

1.3 Color Sensing and Identification

Color sensor systems are being utilized more and more in automated applications to track
quality at production line speed and identify automation problems. They are employed in
assembly lines for product identification and color classification. Their use aims to monitor
waste items, make sorting and packaging easier, evaluate the equality of products in storage,
and check the quality of the products. As a result, color sensors are widely available, and the
selection is frequently based on the application. For less demanding applications where cost
and power consumption are the primary concerns, inexpensive and basic color sensors are
favored over complex ones. It is possible to utilize color names and evoke very consistent
impressions. Eleven fundamental color names, including white, gray, black, red, yellow, green,
blue, orange, purple, pink, and brown, have been identified. Variations and combinations of
colors can be used to characterize most, if not all, colors. It follows that three values are
required and sufficient to characterize any color since three distinct types of cone cells in the
retina contribute to human color perception. The idea of color space originates from color
theory, which states that a point in three dimensions can be represented by any one of three
values. One such color coordinate system is hue, saturation, and brightness.
 CHAPTER 2

LITERATURE REVIEW

A thorough examination of the literature is done on sorting designs that use stepper motors,
Arduino microcontrollers, and color recognition sensors. In order to understand the features
used in the construction of color sorting machines, a survey is done and several methodologies
are implemented.

While there are various kinds of sensors, the majority are electrical or electronic. One kind of
transducer is a sensor. In order for the value detected to be legible by humans, sensors can
either be direct indicators (such as electrical meters or mercury thermometers) or they can be
connected with indicators (perhaps indirectly through a computer, display, and an analog to
digital converter). Sensors are widely utilized in robotics, industry, and medicine, among other
fields. Sorting items by color, or color identification, is a typical demand in the field of color
sensing. Generally speaking, this kind of program is easier to use than a general-purpose color
measurement tool. Determining whether an unknown color belongs to one of these broad
groups is a frequent task in color sensing.

2.1 Color Identification

It is possible to utilize color names and evoke very consistent impressions. White, gray, black,
red, yellow, green, blue, orange, purple, pink, and brown are among the eleven fundamental
color names that have been identified. Variations and combinations of colors can be used to
characterize most, if not all, colors. Since three distinct kinds of cone cells in the retina
contribute to human color vision, it follows that three values are required and adequate to
characterize any color.

2.2 Color Theory

The idea of color space originated with Berlien (2004), who claimed that three values may be
viewed as the coordinates of a point in three dimensions. One such color coordinate system, or
color space, is hue, saturation, and luminance (HSL). Color can be more accurately described
using hue, saturation, and brightness. A color's hue is determined by how closely it resembles
one of the following hues: red, yellow, green, or blue, or by combining neighboring pairs of
these colors into 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 person's eyes and brain interact with a very limited spectrum of electromagnetic radiation to
produce "color." The colors red, green, and blue are merely classifications of what the brain
perceives. According to a brief article by Bishop and Lee (2006), figure 2.4 illustrates the
visible region, which is the range of light that the human eye can perceive. One form of energy
that makes up a tiny percentage of the electromagnetic spectrum is light. Although visible light
can be described as a frequency, its magnitude is so great that people typically describe light's
wavelength in nanometers (10-9 meters). Light having a wavelength falls into the visible light
spectrum.
2.4 Color Sensor

Color sensors use transparent index, contrast, or true color to record objects. One of the color
models—most frequently the RGB model—is the foundation of true color sensors. These three
fundamental hues can be used to produce a significant portion of the visible spectrum. For a
variety of color sorting applications, several color sensors can detect multiple colors.
Depending on the sensor's level of complexity, it can be configured to identify a single color or
a variety of colors or tints for sorting purposes. Certain kinds of color sensors concentrate on
light wavelengths rather than colors. Near infrared (colors in the 750–2500 nm wavelength
range) and far infrared (colors in the 6.00–15.00 wavelength range) wavelengths can be
detected by the sensor. 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

True color recognition requires sensors that can "see" distinct colors or differentiate between
different shades of a single color. They can be utilized in matching or sorting modes. When the
object to be identified is near the designated color in sorting mode, output is triggered. When
the object to be identified is identical (within tolerance) to the color recorded in memory,
matching mode is engaged.

b) Color mark detection.

Instead of detecting the mark's color, color mark detection sensors "see" changes or variations
in the mark when compared to other marks or backgrounds. Another name for them is contrast
sensors. Light is shone onto the object under observation using color sensors, which then
measure the output into color components or the direct reflection. To get the required look,
many color sensors come with built-in light sources. LEDs, lasers, fiber optics, and halogen
lamps are examples of these integrated light sources.
2.5 A review on color sorting system used in various industries and automation/type of
micro controller used in sorting, sensing the objects

According to Akriti Kaushik and Aastha Sharma, a sensor or detector offers a means of
obtaining information about the methods and operations being carried out. In a great number of
cases, sensors are utilized to convert a physical input into an electrical signal that can be
processed by the production machine and used to make decisions about the processes being
carried out. Sensors are used to monitor upload progress, track paintings-in-process using the
production tools, and enable self-monitoring of production using the personal computer of the
manufacturing device. 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.

Depending on the detector's problem, it can be configured to recognize a single hue, several
shades, or sunglasses for classification purposes. This research evaluates coloration detection,
the fundamental shade notion, and, in turn, color detector packages. Those who specialize in
the use of coloration detector victimization conveyor devices are discussed in this article.
According to Tushar G. Gaikar, the framework's main purpose is to divide the object according
to its shading code and distribute it in accordance with its colors. We may determine the color
of the item that is shipped on the line you specify based on this count, and that query is sent to
split .This could be accomplished effectively by utilizing headway as a component of
innovation, specifically in the field of inserted frameworks. These days, a wide range of
beneficial advancements are working to make our way of life more comfortable, opulent, and
cozy. We will be inclined to use shading sensing details and an Arduino controller in this
scenario. This shading detecting device provides a serial yield of RBG fee and can distinguish
shading. 16.7 million shading sunglasses will be identified by it, providing RBG with respect
for the diagnosed shading.

The significant shading is identified with 8-bit accuracy for each of the three key shading
values, namely pink, inexperienced, and blue. Using the RBG values, any shading can be
separated or combined into the three primary colors of red, green, and blue.
A robot that could follow a black line on a white platform, according to Mingwei Liu. This
might be accomplished by employing an array of eight photo resistors. Initially, those sensors
are configured for output. This array will gather light from the environment and convert it into
a virtual signal after a period of delay and port re-entry.

The automaton will use black and white's completely unique mirrored image regularity to
determine whether or not it is now on a line. Because it may affect the sensor's sensitivity, the
put-off time is a crucial element. We repeatedly experimented and found that 200us is a
suitable put-off time for my robot. The automaton might also examine an object's color in
addition to chasing the black line. An RGB color detection sensing element and a distant
infrared sensing detail could be used to accomplish this. The partner degree obstacle gap will
be predetermined by the infrared sensor element. The system will prevent limited motivation
and utilization.

In order to control the actuation portion, we initially used equipment trucks and a twin motor
motive force. However, after adapting my robot's platform, we discovered that the vehicles
were insufficiently effective, so we replaced them with servos. Investigate each habitual
mechanism and patrol on the map. When it identifies an object, it will indicate whether it is
blue or crimson in color. It will turn around and go on if the road ends. The destination is a
white area. After visiting the vacation destination, the robot can pass back.

According to Abhishek Kondhare, Garima Singh, Neha Hiralkar, and M S Vanjale, the project
could be a great way to assess the desire and real-time evaluation of devices in continuous
glide. These days, photo processing attracts a lot of attention since it has the potential to
expand its use in many other industries. The $64000 challenge is to figure out how to make the
current sorting system better inside the stylish system device that has four integrated stations
for sorting, processing, identity, and choosing along with an additional photo system function.
The current sorting technique makes use of a number of optical, electrical, and inductive
sensors that can distinguish between different item shades. This project provides a mechatronic
color sorting machine solution with photo processing equipment. The picture method senses
the objects in this information is processed image system for select-and-vicinity mechanism.
This mission makes use of an automatic material coping with system this is wide utilized in
industries.

Shade plays a crucial role in people's daily lives for reputation, according to M Anil Kumar,
Dr. S A K Jilani, Mr. U Sreenivasulu, and Mr. S Javeed Hussain. The ultimate goal is to create
a version that allows blind folks to see completely distinct colors. The color of their clothing,
the hue of their toys, the color of their pictures, and so on can all be used to predict their
hobbies. This method enables the blind to become familiar with the colors simultaneously
without the use of characters, allowing them to arrange the colors in multiple ways.

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. 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.

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
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.

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 NANO. This task gives high precision and execution. Existing
arranging technique utilizes a lot of inductive, capacitive and optical sensors do separate item
shading.

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.

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
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.

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.

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
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.
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
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.
 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.
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.
 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.
Figure 4.5: parts of two outlets of the sorter
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
b) Servo Motors
 c) TCS230 Color Sensor
a) Arduino NANO

Arduino NANO 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 NANO 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 NANO 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 NANO.

Figure 5.1: Arduino NANO

Specifications:

Table 5.1 represents the specifications of Arduino NANO board.

Table 5.1: Specifications of Arduino NANO board

D1/TX (1) (30) VIN

D0/RX (2) (29) GND
RESET (3) (28) RESET
GND (4) (27) +5V
D2 (5) (26) A0
D3 (6) (25) A1
D4 (7) (24) A2
D5 (8) (23) A3
D6 (9) (22) A4
D7 (10) (21) A5
D8 (11) (20) A6
D9 (12) (19) A7
D10 (13) (18) AREF
D11 (14) (17) 3V3
D12 (15) (16) D13

Pin No. Name Type Description

1-2, 5-16 D0-D13 I/O Digital input/output port 0 to 13
3, 28 RESET Input Reset (active low)
4, 29 GND PWR Supply ground
17 3V3 Output +3.3V output (from FTDI)
18 AREF Input ADC reference
19-26 A7-A0 Input Analog input channel 0 to 7
27 +5V Output +5V output (from on-board regulator)
or Input or
+5V (input from external power
supply)
30 VIN PWR Supply voltage
 a) Servo Motors for Arduino

This High-Torque micro servo 9g SG90 Digital Servo features metal gearing resulting in extra
high 10kg stalling torque in a tiny package. The micro servo 9g SG90 is essentially an
upgraded version of the famous micro servo 9g SG90, 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).

Figure 5.2: SG90 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.

b) TCS230 Color Sensor

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
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.

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 5.4: 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.

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 5.5: Block diagram of operation of system

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
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.
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.
[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.
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

// 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);
 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 = ");
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 = ");
 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");