PLC Operated Color Based Product Sorting Machine
The purpose of this project is to present a Programmable Logic Control (PLC) and SCADA based control system that is applied to the Colour Sorting Machine. In many industrial applications, there is a need of sorting. Sorting can be done by using many ways according to the dimensions, colours, weight,
2025-06-28 16:34:30 - Adil Khan
PLC Operated Color Based Product Sorting Machine
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryThe purpose of this project is to present a Programmable Logic Control (PLC) and SCADA based control system that is applied to the Colour Sorting Machine. In many industrial applications, there is a need of sorting. Sorting can be done by using many ways according to the dimensions, colours, weight, using machine vision (image processing), material of an object etc. For example, in Thermal Power Station, electromagnetic sorting technique is used to sort ferromagnetic materials from coal. This project consists of components such as PLC, SCADA software, conveyors, colour sensors, electronic system and motors. The objects are being sorted according to their respective colour. The main conveyor is supported of two branches to load the distinguished object on to the respective one as separated by the electronic system and detected by the proximity sensors. In this project, SCADA provides a userfriendly environment to establish an easy communication between humans and process. SCADA shows the activation of various parts of the system, i.e. conveyors, motors, LDRs and electronic devices.
Our PLC module consists of the following
• Allen Bradley MICROLOGIX 1200
• 24V DC power module
• 16 digital I/O Module
Understanding the basic features of MICROLOGIX 1200 in our facility would maximize our productivity by increasing the operation of our project. The MICROLOGIX 1200 includes fault detection with built–in diagnostics. Understanding these features is critical in running an efficient operation. Allen Bradley PLC is widely used in several industrial automation operations across Indian sub – continent.
The next concept in our project is of the conveyor belt, on which the objects are kept. Here instead of using multiple conveyor belts for different operation we are using a single conveyor belt which takes the objects to the DC motor where the objects are separated and the sensing of the objects is done and then sorting operation is done simultaneously.
In our project PLC based automatic object sorting machine. We are using an IR Sensor for detection of object presence and Colour sensor for detection of objects based on colour. The operation of IR sensor and Colour sensor are programmed such that when the object comes and when it is detected the sensor senses it for some time delay and if the object is removed during that time delay and placed again then the sensor again starts the sensing time delay from the beginning and after that the instruction of object being sensed is send to the PLC.
Project ObjectivesThe main objective of this project was to develop an object sorting system based on certain specifications. This was successfully implemented. We consider this project as a journey where we acquired knowledge and also gained some insights into the subject which we have shared in this report.
PLC with front end SCADA was used to control the various operations. More features can be added to this system as follows: depending on the size, shape and weight of the objects, sorting operations can be implemented. Sorting operation can be improvised using a piston arrangement.
Project Implementation MethodPLC can be used along with the sensors to achieve a particular tasks since PLC has several advantages over controller to sustain in industrial environment. Moreover to keep the record of production, HMI can be used.
To detect the presence of object, photoelectric sensors are used along with PLC. For sorting the objects, single acting cylinders are used, DC motors used for pushing the object from conveyor belt to sorted bin. Height of object is used as a criteria for sorting.
Figure. PLC Based Sorting
Benefits of the Project
It is very useful in wide varieties of industries along with the help of PLC and SCADA, especially in the packaging process. Automatic sorting machine enhances efficiency, practicality, and safety of operators. It ensures remarkable processing capacity as well as peerless performance including colour 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.
• We can add a load cell for measurement and control of weight of the product.
• We can also add a counter for counting the number of products.
• Speed of the system can be increased accounting to the speed of production.
• The system can be used as a quality controller by adding more sensors.
• The sensor can be changed according to the type of product.
More features can be added to this system as follows: depending on the size, shape and weight of the objects, sorting operations can be implemented. Sorting operation can be improvised using a piston arrangement.
Technical Details of Final DeliverableThe system consists of many functional units such as photo sensor, Colour sensor, Conveyor belt, DC gear Motors .Here PLC plays vital role i.e. it is heart of this proposed system. The PLC is burnt with program that is necessary to control the sensors and relays, and conveyors interfaced to it. The interfaced units are controlled by the PLC in an efficient and faster manner, thus providing the system to be reliable than the existing ones.
Our project is PLC and SCADA based automatic Colour sorting machine divided into four cycles namely: Object Detection, Conveyor starting, Sensory Detection and Sorting mechanism. Our project involves reducing the industrial cost employed in installation and functioning of multiple conveyor belt systems in different industries like Food Processing Industry, Medicine Industry etc. for sorting of different colour objects. This is achieved by setting up a single conveyor belt which carries objects and then the PLC module along with the sensor module which detects the objects and then the objects are sorted accordingly. With this the operational costs, labour costs and installation costs are reduce in manifold by minimal increase of the inputs for the PLC. The ease of use is provided by SCADA.
Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Food , Transportation Core Technology Artificial Intelligence(AI)Other Technologies RoboticsSustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and InfrastructureRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 54400 | |||
| Mitsubishi PLC with GX Developer Ladder Logic Software. | Equipment | 1 | 15000 | 15000 |
| LED Used for interference with PLC. | Equipment | 1 | 8000 | 8000 |
| Colour Sensors | Equipment | 3 | 600 | 1800 |
| Optical IR Motion Sensors | Equipment | 3 | 1200 | 3600 |
| Nema Stepper Motors | Equipment | 3 | 3000 | 9000 |
| Conveyor Belt | Equipment | 1 | 13000 | 13000 |
| Conveyor Belt motor | Equipment | 1 | 1200 | 1200 |
| Conveyor Belt Motor Driver A4988 | Equipment | 1 | 800 | 800 |
| Transportation Charges | Miscellaneous | 1 | 2000 | 2000 |