This project is a production line system designed to automate sorting tasks using a TCS3200 color sensor, IR sensors, servo motors, and a conveyor belt. It integrates advanced features such as a user interface, manual overrides, automatic error detection, and data logging. The project is implemented using the ATmega32 microcontroller.
- Color Detection: Utilizes the TCS3200 sensor with Timer0 and an external interrupt to detect object colors (red, green, blue).
- Object Detection:
- An IR sensor identifies objects approaching the color sensor.
- Three additional IR sensors, paired with SG90 servos and 3D-printed linear actuators to detect object movement near designated actuators.
- Conveyor Belt Control:
- A DC motor, driven by an L298N motor driver and PWM signal from Timer1 to drive a 3D-printed conveyor belt system.
- User Interface:
- Operators can set sorting criteria (e.g., assigning specific colors to bins) via a keypad.
- Displays system status, the number of objects sorted, and real-time error messages on an LCD.
- Manual Override:
- Enables operators to pause the conveyor or shut down the system in emergencies.
- Automatic Error Detection:
- Tracks sorting time to detect jams and sorting errors.
- Routing Circuit:
- A 74139 dual 2-to-4 decoder routes PWM signals from Timer1 to the appropriate servo motor based on a 2-bit control signal.
- A 74147 10-to-4 priority encoder converts signals from four IR sensors (three for servo proximity and one for error detection) into a 3-bit binary value for the microcontroller.
- System Timing:
- Calculates time spent sorting and stores it in EEPROM memory.
- Data Logging and Monitoring:
- Logs the number of sorted objects, sorting time, and error occurrences into EEPROM memory for performance analysis.
- Alerts:
- LEDs indicate production line status (running, paused, or stopped due to errors).
- A buzzer alerts the operator in critical situations.
- Microcontroller: ATmega32
- Color Sensor: TCS3200 with MCU Timer0 and EXTI0 to capture the color frequency and process it
- IR Sensors: Four IR sensors (one for color sensor proximity and three for the sorting mechanism)
- Servo Motors: three SG90 180° servos with 3D-printed linear actuators
- DC Motor: 12v DC geared motor to drive the conveyor belt
- Motor Driver: L298N
- Decoders and Encoders:
- 74139 dual 2-to-4 decoder
- 74147 10-to-4 priority encoder
- Power Supplies:
- 9V 1A power adapter
- 5V power supply
- Display: Character LCD for system status and error messages
- Keypad: 4x1 Keypad For operator input
- Buzzer and LEDs: Three LEDs and a 5v buzzer for system status and alerts
- Additional Components:
- 0.47uF ceramic capacitor and a 1N4004 diode to rectify and smooth current fluctuations from the DC motor
- 100uF electrolytic capacitor to smooth current fluctuations in LCD power supply
- An IR sensor detects an object approaching the TCS3200 color sensor.
- The color sensor identifies the object's color (red, green, or blue).
- Based on the detected color, the routing circuit directs PWM signals to the appropriate servo, moving the object to its designated bin.
- A DC motor drives the conveyor belt.
- Sorting errors are automatically detected and logged for analysis.
- Operators interact with the system through the keypad and monitor the status and errors on the LCD.
- Use the User Interface to set sorting criteria and monitor the process on the LCD.
- Place an object on the conveyor belt.
- The system automatically detects the object's color and sorts it into the correct bin.
- Press '4' to pause the system and again to re-run it.
This project is licensed under a proprietary license. The code and design may be viewed but not used, reproduced, or distributed without explicit permission.
- Abdulrahman Abougendia
- Jana Sherif
- Rokaya Radwan