A low cost intelligent sorting mechanism using infrared and colour sensor with servo driven robotic arm

Abstract

In the era of industrial automation, traditional manual sorting remains a bottleneck characterized by high operational costs and reduced throughput. This research presents an integrated automated sorting system comprising a robotic arm and a conveyor belt mechanism designed to streamline object classification. The system utilizes an infrared (IR) sensor for object detection and a colour sensor for classification based on predetermined criteria. Upon detection, the robotic arm executes precise picking motions to sort objects by colour, significantly minimizing human intervention. Experimental results demonstrate the system's high reliability and efficiency. While the IR sensor consistently detected objects within a 5 cm range, the integration of a physical stopper proved essential for stabilizing object positioning. Initial inaccuracies in colour detection were resolved through iterative frequencyto-red, green, blue (RGB) mapping, eventually achieving 100% accuracy for red, green, and blue targets. Performance tuning revealed that a 1s servo delay optimized the balance between mechanical stability and speed, yielding an average cycle time of 6.66 seconds. With a 95% overall success rate, this system offers a cost-effective automation solution tailored for small and medium-sized enterprises (SMEs) and highlights the scalability of servo-based robotic sorting in manufacturing and recycling sectors.