DEVELOPMENT OF A PROGRAMMABLE LOGIC CONTROLLER SORTING SYSTEM BASED ON COLOR SENSOR IDENTIFICATION

This project involves the design and development of an automated color-based object sorting system controlled by a PLC (Programmable Logic Controller). The primary objective is to efficiently sort objects, specifically color-coded balls (green, blue, and red), using color sensors, a microcontroller (Arduino), and actuators. The system integrates various components, including color sensors (RGB or camera-basesd), microcontrollers for processing sensor data, servo motors for mechanical movement, and electromagnetic actuators to direct sorted objects into designated bins. The PLC coordinates the entire operation, ensuring the sorting process is automated, precise, and fast. The sorting mechanism utilizes a servo motor to transport object, which are then detected by color sensor. Once identified, the sensor triggers actuators to move the objects into the correct bins based on their color. The system’s frame of 1000 mm high with 500 mm wide is constructed from mild steel, selected for its strength and cost-effectiveness. Material properties include a density of 7850 kg/m3, a yield strength of 210 GPa. The frame is designed using square pipes, with the total mass of the frame calculated to be 5.72 kg, resulting in a total weight of 226.3 N. The structural integrity is verified through stress analysis, revealing a maximum axial stress of 2.3 MPa on the vertical members, ensuring that trhe frame can withstand operational loads. The angular velocity is calculated to be 1.57 rad/s2. The torque required to move a ball of 0.02 kg mass along the servo motor is calculated to be 7.85 x 10-5 Nm. The sorting cycle time per ball is 2.5 seconds, consisting of collection, and sorting phases, allowing the system to sort at a rate of 0.4 balls per second or 24 per minute. This performance is achieved with a power consumption of 5 W per servo motor. The sorting system is highly efficient.