PLC-Based Color Sorting with Metal Detection

Abstract

Traditional manual sorting in industrial settings often suffers from inefficiency, high labor requirements, and error-proneness. This study introduces an automated sorting system utilizing a PLC with integrated metal detection to tackle these issues. The system's core is an S-TRONiX 8 I/O PLC, offering a dependable foundation for effective process management. A LX 101 color sensor is incorporated for product sorting based on color, while a metal detector sensor differentiates between metallic and non-metallic items. This combined sorting approach enhances accuracy in handling diverse materials across production lines.The setup includes three actuators driven by RDS 3115MG servo motors, which accurately direct objects to specific bins. A 30 RPM DC geared motor powers the conveyor system, ensuring steady object transport. An L298N motor drive efficiently controls motor functions, and an SMPS provides consistent power to the system's electrical components. NO/NC push buttons allow for secure manual control of the sorting process.The system follows a structured control protocol: objects on the conveyor are first assessed by the metal sensor. Metallic items are redirected to a dedicated container, while non-metallic objects move on to color detection. The LX 101 sensor identifies object colors, triggering the appropriate actuator to sort products into designated bins. This streamlined approach boosts sorting efficiency, minimizes human involvement, and improves production precision.By integrating metal detection and color sorting into a single framework, the proposed system shows marked improvements over conventional sorting methods. It is particularly suited for industries requiring precise material segregation, such as recycling facilities, food processing plants, and packaging sectors. Future enhancements may incorporate advanced sensorsfor size or weight-based sorting, further expanding the system's adaptability in industrial applications.