DEPARTMENT OF MECHANICAL AND ENERGY ENGINEERING

MINS511 EMBEDDED SYSTEMS DESIGN

COLOR SORTING SYSTEM USING ARDUINO AND DIGITAL COLOR

SENSOR

JOSEPH TINKANE | 21000490

JEFFERSON ODIRENG | 24020211

MOGOMOTSI GABOIPHIWE | 22017742

 COLOR SORTING SYSTEM USING ARDUINO AND DIGITAL COLOR
SENSOR

1. Introduction

Automated color sorting is essential in manufacturing, packaging, and recycling, where speed
and accuracy in processing materials are prioritized. This project aims to build a color sorting
system using an Arduino Uno, a digital color sensor, and two servo motors, designed to detect an
object's color and sort it into designated bins.

The project model was first conceptualized using SolidWorks, a 3D modeling tool, to optimize
component alignment and layout for assembly and operation. For testing, colored Skittles were
used to evaluate the system’s color detection accuracy and sorting functionality. This
documentation details the design, assembly, programming, testing, results, limitations, and
potential enhancements.

2. Methodology

2.1 Design

The design process in SolidWorks provided a virtual environment to simulate component

placement and optimize physical alignment:

 Component Alignment: Color sensor and servo motor positions were optimized to
maximize detection and sorting accuracy.
 Bin Layout: Bins were positioned to ensure sorted items could be easily separated.
 Physical Constraints: SolidWorks helped identify potential obstructions, preventing
alignment issues during assembly.

Using SolidWorks streamlined the assembly process by minimizing the risk of misalignments,
enabling efficient physical setup.
Working drawing of color sorting machine
3D model of color sorter

2.2 Components

 Arduino Uno: Central controller for reading sensor data and controlling the servos.
 Digital Color Sensor: Detects Skittles' colors and relays data to the Arduino.
 Servo Motors: Control a sorting arm that directs objects into different bins based on
color.

2.3 Circuit Setup

The digital color sensor connects to the analog pins on the Arduino, while the servo motors are
linked to the PWM pins, allowing real-time color data collection and precise servo actuation.
Circuit diagram for color sorter

2.4 Programming

The Arduino code reads data from the color sensor and adjusts the servo positions based on
predefined color thresholds. Additional comments in the code clarify each function:

* Arduino Project - Color Sorting Machine *

#include <Servo.h>
#define S0 2
#define S1 3
#define S2 4
#define S3 5
#define sensorOut 6
Servo topServo;
Servo bottomServo;
int frequency = 0;
int color=0;
void setup()
{ pinMode(S0, OUTPUT);
pinMode(S1, OUTPUT);
pinMode(S2, OUTPUT);
pinMode(S3, OUTPUT);
pinMode(sensorOut, INPUT);
// Setting frequency-scaling to 20%
digitalWrite(S0, HIGH);
digitalWrite(S1, LOW);
[Link](7);
[Link](8);
[Link](9600);
}
void loop()
{
[Link](115);
delay(500); for(int i = 115; i > 65; i--)
{
[Link](i);
delay(2);
}
delay(500);
color = readColor();
delay(10); switch (color)
{
case 1: [Link](50);
break;
case 2: [Link](75);
break;
case 3: [Link](100);
break; case 4: [Link](125);
break;
case 5: [Link](150);
break;
case 6: [Link](175);
break;
case 0:
break;
}
delay(300);
for(int i = 65; i > 29; i--)
{ [Link](i);
delay(2);
}
delay(200);
for(int i = 29; i < 115; i++)
 {
[Link](i);
delay(2); } color=0; }
// Custom Function - readColor()
int readColor() {
// Setting red filtered photodiodes to be read
digitalWrite(S2, LOW); digitalWrite(S3, LOW);
// Reading the output frequency
frequency = pulseIn(sensorOut, LOW);
int R = frequency;
// Printing the value on the serial monitor
[Link]("R= ");
//printing name
[Link](frequency);
//printing RED color frequency
[Link](" "); delay(50);
// Setting Green filtered photodiodes to be read
digitalWrite(S2, HIGH);
digitalWrite(S3, HIGH);
// Reading the output frequency
frequency = pulseIn(sensorOut, LOW);
int G = frequency;
// Printing the value on the serial monitor
[Link]("G= ");
//printing name [Link](frequency);
//printing RED color frequency [Link](" ");
delay(50);
// Setting Blue filtered photodiodes to be read
digitalWrite(S2, LOW);
digitalWrite(S3, HIGH);
// Reading the output frequency
frequency = pulseIn(sensorOut, LOW);
int B = frequency;
// Printing the value on the serial monitor
[Link]("B= ");

//printing name
[Link](frequency);
//printing RED color frequency
[Link](" ");
delay(50);
if(R<45 & R>32 & G<65 & G>55){ color = 1;
// Red
}
if(G<55 & G>43 & B<47 &B>35){ color = 2;
// Orange
}
if(R<53 & R>40 & G<53 & G>40){ color = 3;
// Green
}
if(R<38 & R>24 & G<44 & G>30){ color = 4;
// Yellow
}
if(R<56 & R>46 & G<65 & G>55){ color = 5;
// Brown
}
if (G<58 & G>45 & B<40 &B>26){ color = 6;
// Blue }
return color;
}

3. Results

Testing with various Skittles colors yielded the following performance metrics:

 Color Detection Accuracy: Approximately 85% accurate in distinguishing primary

colors (red and blue), though minor adjustments were needed for green and yellow
Skittles.
 Sorting Speed: Capable of sorting one Skittle every 1.5 seconds.
 Reliability: Consistent operation for 30 minutes, with no interruptions in performance.

4. Limitations and Future Improvements

Limitations:

1. Color Range: Limited differentiation with subtle color shades.

2. Lighting Dependence: Environmental lighting affected detection accuracy, requiring
recalibration.
3. Mechanical Adjustments: Servos required periodic realignment to maintain sorting
accuracy.

Future Improvements:

1. Enhanced Color Detection: Using an advanced sensor could improve color accuracy.
 2. Lighting Stabilization: Adding controlled LED lighting around the sensor could reduce
dependency on ambient lighting.
3. Automated Calibration: Implementing a calibration routine at startup could improve
adaptability.
4. Extended Sorting Capabilities: Adding more bins and servo positions could enable
sorting of additional colors.

5. Calibration Steps for Different Environments

To ensure consistent color detection in different lighting conditions, the following calibration
steps are recommended:

1. Indoor Fluorescent Lighting:

a. Use reference Skittles (e.g., red and blue) to observe sensor values.
b. Set color thresholds based on these readings, as indoor lights can introduce
shadows.
2. Natural Daylight:
a. Observe color readings at different times to account for light changes, adjusting
thresholds to mid-range values for consistency.
3. Low-Light Conditions:
a. Increase sensor threshold values to maintain detection in dim lighting, or add
LED lighting to create a controlled environment.
4. Mixed Lighting:
a. Test reference Skittles in multiple positions, then average the readings to set
balanced thresholds.

6. Code Optimization for Improved Sorting Efficiency

Potential Code Optimizations:

1. Reduce Delay Duration: Lowering the delay to 500 ms instead of 1000 ms could
increase sorting speed without impacting accuracy.
2. Adaptive Thresholding: Implement a self-calibrating routine to adjust thresholds at
startup for minor lighting changes.
3. Interrupt-Based Control: Switching to interrupt-based servo activation could reduce
redundant movements.
4. Streamlined Sorting Logic: Refactoring the sorting logic with a switch-case structure
could simplify code for future expansions.
7. Conclusion

The color sorting system successfully demonstrated an automated sorting solution for Skittles
based on color, supported by the Arduino and servo motors. SolidWorks modeling facilitated
accurate component alignment, which streamlined assembly and optimized operational
reliability.

Additional Applications

Potential real-world applications include:

 Recycling and Waste Management: Sorting recyclables by color.

 Pharmaceutical Sorting: Organizing pills by color for quality control.
 Food and Beverage Industry: Sorting colored items like candy in packaging lines.

With further development, this system could inspire larger-scale sorting solutions in industrial
settings.

8. Troubleshooting and Calibration

Common Issues:

 Inconsistent Detection: Recalibrate if lighting changes, or add controlled lighting to

stabilize readings.
 Servo Misalignment: Regularly check servo alignment to maintain accuracy.

Calibration Guide:

 Use the Serial Monitor to read sensor values and adjust thresholds based on multiple test
objects.
 Refine color thresholds as necessary to ensure reliable sorting across various colors.

9. Challenges faced during project implementation

1. Limited equipment: this resulted in us not being able to complete the assembly of the
hardware components.

2. Faulty components: some of the components like the color sensor could not produce reliable,
consistent output.