A

PROJECT REPORT
ON

Robotic Arm-Based Object Sorting System

Submitted in the partial fulfillment of the requirement for the award of the diploma

in

AUTOMATION & ROBOTICS ENGINEERING

Submitted by,

“Roll No.: 12 Rohan Gangaram Kokatare”

“Roll No.: 03 Saurabh Bachchalal Yadav”
“Roll No.: 22 Aryan Jaiprakash Tiwari”
“Roll No.: 11 Utkarsh Pravin Chauhan”

UNDER THE GUIDANCE OF

Mr. KISHOR FARDE

DEPARTMENT OF AUTOMATION & ROBOTICS ENGINEERING

SHIVAJIRAO. S. JONDHLE, POLYTECHNIC

ASANGAON
[2024-2025]
 Vighnaharata Trust’s

SHIVAJIRAO S. JONDHLE POLYTECHNIC, ASANGAON

Institute Code: 0935
(Affiliated to Maharashtra State Board of Technical Education, Approved by AICTE)
Department of Automation & Robotics Engineering
2024-2025

CERTIFICATE

The project report entitled “Robotic Arm-Based Object

Sorting System” submitted by MR. ROHAN KOKATARE, MR. SAURABH YADAV,
MR. UTKARSH CHAVAN & MR. ARYAN TIWARI are approved for the Diploma in

Mechanical Engineering from Maharashtra State Board of Technical Education,

Mumbai.

Mr. Kishor Farde Mr. Kishor Farde. Dr. Anwesh K. Virkunk

Guide Head of Department Principal

External Examiner Sign

Date:
Place:
 ACKNOWLEDGEMENT

It gives me a great pleasure to submit this project report on “Robotic Arm-Based Object
Sorting System”. I express my sincere thanks to my guide Mr. Kishor Farde for his/her guidance
and time to time valuable suggestion and providing constant support throughout this work.
I am very thankful to the staff members of Automation & Robotics engineering department for
their persistent inspection inspiration.
I am also very much thankful to Principal, Dr. Dr. Anwesh K. Virkunk who has been a
constant source of inspiration to complete the work.

Name of Student:
Rohan Gangaram Kokatare
Saurabh Bachchalal Yadav
Aryan Jai Prakash Tiwari
Utkarsh Pravin Chavan
 ABSTRACT NO: 1

ABSTRACT:

This project presents the design and implementation of an automated color-sorting robotic arm
integrated with a conveyor belt system, controlled by an ESP32 microcontroller. The system
utilizes a TCS3200 color sensor for precise color detection and sorting, making it ideal for
industrial applications such as manufacturing, packaging, and recycling. The ESP32 processes
real-time color data and coordinates the robotic arm’s servo motors to pick up and place objects
into color-coded bins.

The setup features a conveyor belt to transport objects into the detection zone, an IR sensor for
object presence detection, and an LCD display to show real-time feedback, including the count
of sorted items. Push buttons enable user control for starting, pausing, or stopping the
operation. This fully automated system reduces manual labor, minimizes errors, and improves
operational efficiency by quickly sorting objects based on color with high accuracy. The project
provides a cost-effective and scalable solution, with potential for future enhancements such as
machine learning or advanced vision systems for increased flexibility.
 INTRODUCTION
The robotic arm for color sorting operates through an integrated system of sensors, actuators,
and a microcontroller. At its core is the ESP32 microcontroller, which manages the various
components of the system. The process begins with an IR sensor that detects the presence of
objects moving along a conveyor belt. Once an object is detected, the system activates the
TCS3200 color sensor to analyze the color of the object. The TCS3200 sensor uses light-to-
frequency conversion to provide accurate color readings, enabling the ESP32 to make real-
time decisions based on the detected color.

After the color data is processed, the ESP32 directs the robotic arm's servo motors to pick up
the object and place it into the corresponding color-coded bin. The robotic arm is equipped
with high-torque servos, ensuring precise movement to handle objects of various sizes and
weights. The servo-driven movements allow for quick and accurate sorting, improving
operational efficiency and reducing the potential for human error.

This system is designed to be cost-effective and compact, making it suitable for industrial
environments where space and budget are often constraints. The modular nature of the system
also ensures scalability, as additional bins or sorting stations can be added to meet the
increasing demands of production lines. The combination of high-speed sensors, precise
actuators, and an intelligent control system makes this robotic arm an ideal solution for
applications in manufacturing, packaging, and recycling, where high-throughput sorting is
crucial.
Resources Used:
Sr.no Name of resource Specifications Qty

1 Robotic Arm 6DOF, made of PLA filament with 1

servo-controlled gripper for handling
objects of various color

2 ESP32 ESP32 Microcontroller: Controls 1

the robotic arm, conveyor belt, and
sensors with built-in Wi-Fi and
Bluetooth capabilities.

3 PCA9685 servo driver PCA9685 Servo Driver: A 16- 1

channel PWM driver used to control
multiple servo motors with high
precision, allowing smooth arm and
conveyor movement.

4 MG995 servo motor MG995 Servo Motors: High-torque 4

metal gear 360 degree rotational
servos used to control conveyer
machine with smoothl.
5 MG90s servo motor MG90S Servo Motors: Compact 3
metal gear servos, likely used for
lighter movements or smaller degrees
of freedom on the arm and to control
the movement of gripper.

6 IR sensor IR Sensor: Detects objects on the 1

conveyor belt, triggering the color
detection and sorting process.

7 TCS3200 color sensor TCS3200 Color Sensor: Detects the 1

color of objects, enabling the sorting
functionality by sending color data to
the ESP32.

8 Leather or rubber belt Leather or Rubber Belt: Acts as the 1

conveyor belt material, offering grip
for smooth object transport.
9 LM2596s buck converter LM2596S Buck Converters: Step- 2
down converters used to provide a
stable lower voltage to the ESP32 and
servo driver, ensuring efficient power
regulation.

10 20x4 LCD with I2C display 20x4 LCD with I2C Display: 1
Displays the count of sorted objects
and system status information.

11 SPST push button SPST Push Buttons: Simple 3

switches to start, pause, and stop the
system operation as needed.

12 12V 10A SMPS 12V 10A SMPS: Provides a stable, 1

high-current power source for the
entire setup, ensuring all components
run efficiently.
13 Wiring and Connecter Various cable, connector and wiring
for the electrical component.
Methodology:

1. System Initialization: Power the system using the SMPS. The ESP32, servo driver, and
sensors are initialized, and the LCD displays “System Ready”.

2. Object Detection: The IR sensor monitors the conveyor for objects. When an object is
detected, the conveyor stops for color scanning.

3. Color Detection: The TCS3200 sensor reads the RGB values of the object, which the
ESP32 processes to classify the color based on set thresholds.

4. Decision-Making and Sorting: Color Matches Preset: The ESP32 sends a command to the
robotic arm to pick and place the object in the appropriate bin.

Color Does Not Match*: The conveyor resumes, moving the object forward.

5. Robotic Arm Operation: The servo motors move the arm to pick up the object and place it
in the designated bin.

6. Display and Count Update: The LCD updates the total count of sorted objects and system
status.

7. User Controls:
Stop: Halts all operations and shut down the hold system.

Pause: Pauses the process and waits for a resume command and also use for emergency stop.

Run: When power supply on is start the system and restarts the system after a pause.

8. Loop Back: The system resets to the object detection stage and repeats the cycle.

Applications:

Manufacturing: Automates the sorting of components by color, ensuring efficient assembly

and quality control.

Packaging: Sorts products like bottles or food items by color for accurate packaging.

Recycling: Separates recyclable materials (plastics, metals, etc.) based on color to improve
sorting efficiency.

Agriculture: Sorts fruits and vegetables by ripeness or color for quality control in food
processing.

Textiles: Sorts fabrics by color for dyeing or assembly in the textile industry. Textile and
Garment Industry: Sorts fabrics and clothing items by color for organized handling in
warehouses or during packaging.

Challenges:

- Real-Time Processing: Ensuring swift detection and arm movement.

- Lighting Variability: Adjusting to lighting changes to maintain color accuracy.

- Sensor Calibration: Fine-tuning TCS3200 for subtle color distinctions.

- Object Orientation: Maintaining consistent positioning for accurate detection.

- Synchronization: Coordinating conveyor and robotic arm movements.

FUTURE ENHANCEMENTS:
Machine Learning Integration: To enhance color detection and sorting under varied conditions.

Adaptive Lighting: Using LEDs for consistent illumination.

Advanced Vision Systems: Employing camera-based systems for additional object recognition
features.
Conclusion:

The ESP32-controlled robotic arm and conveyor system, integrated with the TCS3200 color
sensor, provide a robust and efficient solution for color sorting in industrial environments.
This system excels in quickly and accurately identifying and sorting objects based on their
color, making it ideal for tasks in manufacturing, packaging, recycling, and other sectors
where high-speed, precise sorting is crucial. The ESP32 microcontroller processes the data
from the TCS3200 sensor in real-time, directing the robotic arm to pick up and place items in
designated bins, thus automating the sorting process and enhancing operational efficiency.

Looking ahead, the system’s capabilities can be further expanded with the integration of
advanced vision systems, such as cameras with object recognition software. These systems
could complement or replace the TCS3200 sensor for broader color detection or to identify
additional object characteristics like shape or size. Furthermore, incorporating machine
learning algorithms could enable the robotic arm to adapt to changing environments and
improve sorting accuracy over time by learning from data patterns. Optimizing lighting
conditions in the detection zone can also improve the system's accuracy, ensuring consistent
color readings even in varying lighting environments. With these potential improvements, the
system would become even more flexible, able to handle complex sorting tasks and offer
greater adaptability to diverse industrial applications.

REFERENCE:

https://www.espressif.com/en/products/socs/esp32
https://lastminuteengineers.com/tcs230-tcs3200-color-sensor-arduino-tutorial/
https://www.adafruit.com/product/815
https://www.winstar.com.tw/products/character-lcd-display-module/20x4-lcd-
display.html
https://www.researchgate.net/publication/373739005_Color_sorting_robotic_arm