A Color Sorting Device is an automated system that detects the color of objects and sorts them into different categories accordingly. These systems are widely used in manufacturing, packaging, agriculture, and recycling industries.

In this project, we build a smart color sorting machine using Arduino. The system uses a TCS3200 color sensor to detect the color of objects and sorts them into bins using servo motors. Additional components like IR sensors, conveyor belts, and LCD/OLED displays can enhance the functionality, accuracy, and usability of the device.

Components Required for Color Sorting Device:

Working Principle of Color Sorting Device using Arduino:

1. Object Detection: An IR sensor detects the presence of an object near the color sensor.
2. Color Sensing: The TCS3200 color sensor reads the RGB values of the object.
3. Data Processing: Arduino compares the RGB values with predefined thresholds to identify the color (e.g., red, green, blue).
4. Sorting Mechanism: Based on the detected color, a servo motor rotates to a specific angle and directs the object into the correct sorting bin.
5. Repeat: Once sorted, the system resets and waits for the next object.

Working of TCS3200 Color Sensor:

• The TCS3200 sensor contains an array of photodiodes with red, green, and blue filters.
• It converts light intensity into a square wave frequency.
• By reading the frequency for each color filter, we estimate the RGB components of the detected object.

Circuit Diagram of Color Sorting Device using Arduino:

Arduino Code for Color Sorting Device:

#include <Servo.h>

Servo sorterServo;

// Example pins for TCS3200
const int S0 = 4;
const int S1 = 5;
const int S2 = 6;
const int S3 = 7;
const int sensorOut = 8;

int redFrequency, greenFrequency, blueFrequency;

void setup() {
  sorterServo.attach(9);
  pinMode(S0, OUTPUT); pinMode(S1, OUTPUT);
  pinMode(S2, OUTPUT); pinMode(S3, OUTPUT);
  pinMode(sensorOut, INPUT);
  
  digitalWrite(S0, HIGH); // Scaling
  digitalWrite(S1, LOW);
  
  Serial.begin(9600);
}

void loop() {
  // RED
  digitalWrite(S2, LOW);
  digitalWrite(S3, LOW);
  redFrequency = pulseIn(sensorOut, LOW);
  
  // GREEN
  digitalWrite(S2, HIGH);
  digitalWrite(S3, HIGH);
  greenFrequency = pulseIn(sensorOut, LOW);

  // BLUE
  digitalWrite(S2, LOW);
  digitalWrite(S3, HIGH);
  blueFrequency = pulseIn(sensorOut, LOW);
  
  Serial.print("R: "); Serial.print(redFrequency);
  Serial.print(" G: "); Serial.print(greenFrequency);
  Serial.print(" B: "); Serial.println(blueFrequency);

  // Basic threshold example (should be calibrated)
  if (redFrequency < greenFrequency && redFrequency < blueFrequency) {
    sorterServo.write(0); // Red bin
  } else if (greenFrequency < redFrequency && greenFrequency < blueFrequency) {
    sorterServo.write(90); // Green bin
  } else {
    sorterServo.write(180); // Blue bin
  }

  delay(1000);
}

Arduino Logic Overview:

1. Calibrate RGB values for each color.
2. Use pulseIn() function to read frequency from the TCS3200.
3. Compare with calibrated values to identify the color.
4. Rotate the servo motor accordingly.
5. Optional: Use OLED/LCD to show detected color.

Mechanical Setup of Color Sorting Device:

• Create a chute or sloped surface to drop colored balls/caps onto a scanning area.
• The IR sensor is positioned before the color sensor to detect when the object is ready to be scanned.
• The color sensor is fixed below or beside the object detection area.
• The servo motor is placed underneath or beside the object drop zone and has a flap or rotating arm to divert objects into bins.

Optional Features for Color Sorting Device:

Applications of Color Sorting Device:

1. Food Industry:
   • Sorting colored candy, pills, or jelly beans
   • Detecting fruit ripeness by color
2. Recycling Centers:
   • Sorting plastic bottle caps or labels by color
   • Separating recyclable materials
3. Manufacturing:
   • Quality control based on part color
   • Packaging different colored products
4. Agriculture:
   • Sorting beans, seeds, or grains
   • Removing discolored or defective items
5. Education / STEM:
   • Demonstrating automation and sensor control in schools
   • Great project for robotics and Arduino learning
6. Medical / Pharmaceutical:
   • Sorting capsules or tablets by coating color

Future Expansion Ideas for Color Sorting Device:

• Add AI-based color recognition using a camera and Raspberry Pi.
• Use a load cell to weigh objects before sorting.
• Add bin level detection sensors to alert when full.
• Connect to cloud database to log sorted quantities and types.
• Enable voice alerts using DFPlayer Mini MP3 module.

Conclusion

The Arduino-based Color Sorting Device is a practical and scalable solution for real-time color-based automation. It demonstrates a perfect blend of sensors, actuators, and logical control systems.

With a simple mechanical structure and smart code, you can create a reliable sorting system that can be used in various industries and learning environments. Whether it’s for fun, education, or industrial use, this project teaches the fundamentals of automation, color detection, and robotics with Arduino.

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