Research Paper Example on Color Sorting Machines

Introduction

In our daily activities, we encounter different items occurring with different colors. These items contain specific colors that a manufacturer purposely assigns them depending on their use. Miyamoto (2015) outlines the components of color that enable the human eye to differentiate between two objects as hue, saturation, and luminance. These components help when there is a need for large-scale separation of items of different colors. Although a human eye has cone cells containing elements that are responsible for distinction of the various types of colors, it lacks the ability to sort item with a narrow distinguishing property. This limitation necessitates the use of color sorting machines.

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Product Research

Traditionally, the process of color separation was done using color filters (Boopathy & Ramkumar, 2016, p.57). However, the process experienced numerous setbacks arising from lower daily production rate. Previous studies show the application of various color sorting techniques in industrial setup. For instance, the operator places the items to be sorted on a conveyor belt which works together with technologies like servo motors and Arduino. Also, the use of computers eases the process of distinguishing colors. In this process, recognition of the distinct colors sends the information back to the servo motors with a robotic arm that picks items of similar colors to one section.

According to Sofu (2016), the use of a microcontroller to move signals into the robotic arm is evidence in developing color sorters. Upon detection of a color, the arm moves back to its original position and picks the identified color. This process enables automatic highspeed sorting process. Another journal discussed the use of; color sensor, stepper, servo motors, and microcontroller. In this approach, the microcontroller replaces the camera and moves the signals to the robotic arm on the items introduced to the conveyor belt. The items are picked based on their colors and are prepackaged on a specific section. Upon detection of a given color, the robotic arm moves back to the original position and picks the identified color. All this process is done by using color sensor technology and enables the industries to be fast and the sorting process to be synchronized and automated. The reduction of human labor enables the industries to save on cost and time.

Also, there is an increased use of color sorting system video camera that transfers information on the sensors (Sofu, 2016, pp.395-405). This system was mostly used in fruits and vegetable industry in which the color sorter identified the items desired. Those objects the system could not pick constituted an unacceptable sequence of colors. The technology which uses a camera instead of a video in the conveyor is effective in sorting out the various products in industrial markets.

Components of The Color Sorting Machine

The machine consists of an Arduino UNO which controls every part of the machine. A 12-volt external power source powers the servo motors. The system has programming codes that run the machine in real-time. Controlling Motor arranges the chute according to the color which the sensors identify. This allows packaging in specific different containers. Color sorting contains a rotating object picking and a stagnant object carrying part (Henry & Jie, 2017, P.36-40). The colors in the object picking part facilitates identification process. Chute Section consists of the shaft which collects objects as sorting proceeds. DC motors directs the electrical power to mechanical power which enables the robotic arm to move back and forth. The motors constitute of internal electronic or electromechanical energy which directs the flow of the motors by producing a force. The speed of this motor can be controlled by adjusting the power supply to it. It constitutes of stator and rotator.The normal amount of power needed by such motor is 250mA. Hence the Arduino Uno cannot be able to provide such energy by itself arising the need of alternative power source (Alekhin et al., 2013, p. 114). An example of alternative power sources includes interfacing using transistors and interfacing using relays. A Servo Motor is a rotatory device that allows for angular movement of the robotic arm responsible for sorting items of a given color in the conveyor belt. It has a sensor and motor responsible for positioning. They are controlled by sending signals regarding electrical pulse with modulation (PWM), it can move a total of 180 degrees, i.e., 90 degrees clockwise and 90 degrees anti-clockwise. The strength of the pulse sent determines the length which the motor will rotate or move. The pulse must be sent repeatedly if a motor is desired to maintain a given position.

Two main types of color sorting machines are industrial made and homemade color sorters. Miyamoto (2015) explains that industrial design sorters will require greater installation resources compared to home-made machines. This fact eliminates low class population who wish to employ this technology in their daily chores. Consequently, using off-the-shelf components, hobbyists develop a homemade color sorter that fits the needs of many households. The following brief review of the two level of color sorters.

Industry-Based Color Sorter

General Appearance of an Industry-Based Color Sorter

The operator directs want he/she wishes to sort into the system through a vibratory feeder. The objects proceed to the proximity sensors where the system depicts maximum output frequency. Sensors send signals to control systems and objects are sorted based on the distance between them and the sensor. Because of the different parameters like hue and color brightness, the machine detects variation in the photoelectric properties and sends signals to an ejector that splashes out undesirable objects.

Home-Made Color Sorter

General Appearance of a Home-Made Color Sorter

This machine consists of a funnel which directs objects into the system. Provided the objects to be sorted have a regular and even shape, the machine uses the RGB sensor to detects and categorize different type of items. Once in motion, sorting proceeds at the speed of the motor.

Design Specifications of Color Sorting Machines

Color sorting machines exist in different form, depending on their specific use. These machines can sort different materials including beans, rice, and all types of grains. This work analyses candy sorting machine. Simple material including a funnel, a clear cube container, a photoelectric sensor and a supply of current, all of which are off-the-shelf materials are assembled to form this machine. An average of four hundred and fifty pounds is sufficient to assemble this product. A one-year functioning period is adequate for machines before it requires maintenance activities. Because of the simple materials, maintenance costs are reasonably manageable. Also, the machine is environmental pollution free due to its simple components.

Design Concepts and their Evaluation

Every color sorting machine has different design concept. For the success of the products, design teams need to understand the goal of the design, the users of your product and what is the product about (Henry & Jie, 2017, pp.36-40).

Automatic Color Sensor Concept

Diagrammatical Representation

Sorting of products is a strenuous and erroneous process when done manually. This piece illustrates an automatic sorting design of objects. This machine employs a TCS230 sensor as its product color detector and type PIC16F628A of microcontrollers that controls the process. The system identifies colors using frequency analysis of TCS230 output. Two conveyor belts are used each connected to its own direct current supply motor. Product to be examined by the color sensor is placed on the first belt, moves along with the container with already separate compartments in order to isolate the products. The type shows a great potential in fulfilling the needs for higher production and quality in the automation field.

Evaluation

Automatic processor depicts a number of advantages. Firstly, this machine offsets the inaccuracy issues that are common with manual sorting. The sensors and the conveyor belts work perfectly to produce the desired result. There is less manpower in using these machines. Thus, human labor is reduced in organizations. There is a faster rate of getting results. Therefore, this increases the production rate in companies. The machines can also run all day and night without much human interaction.

The main disadvantage of the automatic color sorter is its complexity in operation. Also, the machine requires large amount of money to install. There are some technical problems which result in errors during the isolation of contaminated and fresh fruits.

The Arm Processor Concept

Diagrammatical Representation

This system helps to counter the problem of huge systems that were more power consuming with the high cost of running. Color images usually show lighting conditions that will be overcome using arm processor system. The camera and lighting are usually calibrated in case there is a need for precise results. This system has three sections including electric control, image processing and grains sorting systems. The pick-up arm drive enables picking of grains, while the image processing method is used for color processing. A wince system accompanies the ARM processor while color sorting is done using a CMOS camera.

Evaluation

Arm processors color sorting machines help in the reduction of the initial sizes of another sorter. This help controls the space required to mount such a gadget. Also, the machine helps in reducing the level of output as large quantities of items are sorted in less time compared to manual sorting. Also, the overall human effort required to produce the same results drops down and is directed to other sectors of production. The machines help in reducing the long run costs of production.

The Extensive RGB Concept

Diagrammatical Representation

The system works by separating the item basing on their shading code referred to as hue. This is affected by utilizing headway in the field of inserted frameworks. The system utilizes the controller and shading detector. The sensor differentiates the shading and assigns it RBG worth code. This system can differentiate 16 million shadings. The system recognizes the shadings as a measure of Red, Green and Blue shadings and consolidates them into three vital hues namely Red, Green and Blue using the RBG values.

Evaluation

RGB machines provide a conveyor that enables easy transportation of the objects from the entry point to the point of separation. This gives room for large quantities of objects to be worked on. The machines also simplify recognizing and differentiation of the colors. The system also facilitates the implementation of an industrial assembly line with the methodology in image processing, an activity that proves difficult for other sorting mechanisms. It also aids in the provision of reliable series of Atmega regulators in Arduino.

Despite their use, this machines still needs human-automation labor to control the fruits into the color sorting machine which in the long run still expose them to risk of infection. Like all the other machines, this type also cuts down on human involvement, a trend that can lead to inactive population in terms of technical aspects.

In general both the home-made and industrial color sorters employ the use of Arduino Uno to help in the color sorting process. Moreover, color sensors and servo motors are needed in both machines to sort the items basing on their color effectively. The designs of both the home-made and industrial based color sorting machines consist of the various sections which th...