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PLC Based Object Sorting System Using Image Processing

Article · May 2021

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 05 | May - 2021 ISSN: 2582-3930

PLC Based Object Sorting System Using Image Processing

Prof. Manisha Bhole1, Rahul Bamane2, Rohit Jadhav3, Prafulla More4, Rohit Ture5.
1
Prof. Manisha Bhole,Instrumentation Engineering, Bharati Vidyapeeth College of Engineering, Maharashtra, India.
2
Rahul Bamane, Instrumentation Engineering, Bharati Vidyapeeth College of Engineering, Maharashtra, India.
3
Rohit Jadhav, Instrumentation Engineering, Bharati Vidyapeeth College of Engineering, Maharashtra, India.
4
Prafulla More, Instrumentation Engineering, Bharati Vidyapeeth College of Engineering, Maharashtra, India.
5
Rohit Ture, Instrumentation Engineering, Bharati Vidyapeeth College of Engineering, Maharashtra, India
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ABSTRACT–Object sorting is needed in such as sorting tablets in the medical industry. In the
manufacturing industries. Objects can be of various mechanical industry, it can also be used to sort nuts and
shapes and colours, or they can be the same shape and bolts. Since it needs less manpower and is more reliable,
colour. As a result, various objects and parameters need this system is more common. The objectives of this
different types of processing. The aim of this project is to project are as follows:
identify objects using various image processing
1.Manufacturing and assembly of sorting system.
algorithms based on colour and shape parameters. An
image will be used as the system's input, which will be 2.Image processing of object using camera and results are
processed to detect colour or shape, and the object will obtained for sorting the object.
then be sorted accordingly.
3.Interfacing of image processing software i.e. Raspberry pi
Keywords-Digital image processing, OpenCV Python, with PLC.
Raspberry Pi, Programmable Logic Controller (PLC),
Object sorting. II. BLOCK DIAGRAM

I. INTRODUCTION

The food processing and handling industry is one of the

fastest growing sectors, with applications such as cutting,
baking, packaging, grading, and sorting of different food
products. In the food industry, automated sorting systems
are commonly used. In this system, object would be
sorted according to colour and shape. It uses integration
of RASPBERRY PI and PLC for sorting. Effectively it
reduces the labour and working time. Reduced manual
handling allows for effective and hygienic object sorting.

Many years ago, when the need for object sorting arose, it
was done manually. To address the drawbacks of the
Fig. 1 Block Diagram
traditional sorting system, an automated object sorting
system is needed. Block Diagram consist of Raspberry Pi Camera Module,
Raspberry Pi 3B+, PLC, Conveyor Belt,Actuator and
Image processing technique is used to sort objects in an
Proximity Sensors. In this Proximity Sensors are connected to
automated object sorting system. Objects are sorted
the Input Module of PLC. Raspberry Pi Camera Module is
without harm and in less working hours thanks to this
connected to the USB ports of Raspberry Pi. Raspberry Pi is
automated method. As a result, it is used to sort objects in
connected to PLC via MODBUS. We have used PLC as
the food industry.It has a wide range of other applications,

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 05 | May - 2021 ISSN: 2582-3930

Primary controller to control Conveyor Belt and Actuator. IV. HARDWARE AND SOFTWARE
Conveyor Belt and Actuators are connected to the Output
Module of PLC. HARDWARE:
III. WORKING 1.PLC:

PLC is used for controlling the motion of conveyor.

Interfacing of PLC with Raspberry Pi is done through
MODBUS.

Specification:

PARAMETERS SPECIFICATION

Company DELTA

Model No. DVP SA2

Software ISP SOFT

Inputs 8 DI

Outputs 4 DO
Here, when start button is pressed then conveyor motor will be
Scan Time 0.1 msec
started. By using proximity sensor, the conveyor motor
stopped when object will come below the camera. Then the COM Port Built in RS232 and Two RS485 Ports
image of the object will be taken by camera for image compatible with MODBUS ASCII/RTU
processing. After that if the shape and colour of the object is Protocol
OK then it will proceed to the end of the conveyor and then it
will go into the bin 1.If shape and colour of the object is not
OK then actuator will separate that object into bin 2.
Program Capacity 16 K Steps

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 05 | May - 2021 ISSN: 2582-3930

2. RASPBERRY Pi 3B+:

A gear motor is used to keep the conveyor belt moving at a

slow speed. It aids in slowing down the conveyor speed. It
should be driven at a speed of 30-60 RPM.

6. Single Acting Pneumatic Actuator:

Raspberry Pi 3B+ module has 40 GPIO pins.It has 4 USB
ports to connect keyboard, mouse, web camera and Dexter Er2
Robotics.HDMI cable used to connect the monitor.USB port
is used to give supply to Raspberry Pi 3B+.

3. Raspberry Pi Camera Module:

The piston or diaphragm of a single acting pneumatic actuator

is driven by compressed air, which compresses a spring in one
direction and then exhausts the air displaced on the opposite
side, allowing the piston or diaphragm to move. To keep the
springs from releasing, the compressed air is retained.When
the piston or diaphragm is forced to move upward, the
compressed air is released and the energy contained in the
springs is used to propel the piston or diaphragm to its
maximum travel.
This Raspberry Pi Camera Module Board is a high-resolution
5 MP camera that can take high quality pictures. It does not 7. Solenoid Valve:
only take pictures but also shoot videos, making it suitable for
drones, CCTV, and other Raspberry Pi projects. A fixed lens
with a resolution of 5 MP is built into the camera board. This
camera board has a resolution of 2592*1944 pixels and can
capture photographs.
4.Proximity Sensors:

A solenoid valve is a valve that is operated by

electrochemically. An electric current is used to control the
valve through a solenoid. The solenoid and valve are the two
main components of a solenoid valve. The solenoid convert
electrical energy into mechanical energy, which is then used to
open or close the valve mechanically.

For sensing object, three capacitive proximity sensors with a

range of 5 to 7 cm are provided. These will be used to detect 8.Bins:
the object on the conveyor and, if necessary, to stop it.
The sorted items will be placed in two bins. Objects with the
5. Gear Motor: right shape and colour are placed in one container. Objects
that are defective are placed in the second bin.

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 05 | May - 2021 ISSN: 2582-3930

SOFTWARE: VI APPLICATIONS
Image Processing: This sorting system can be used in a wide range of
applications. The following are some examples:
Image processing is a form of signal processing in which the
input is an image such as a picture, video, or other visual •Medical Field:This procedure may be used to sort tablets or
representation. This may produce an image or a collection of capsules of various shapes and colours in the medical field.
image characteristics as a result. Optical and analog. Image
•Mechanical Industry:In the mechanical industry, it can be
processing are also possible here. However, the term "digital
used to sort nuts and bolts of various shapes and colours.
image processing" is also used. This is closely connected to
computer graphics and computer vision techniques. •Food Industry: This can be used to sort fruits and vegetables
by colour and shapes.
1.OpenCV Python:
The OpenCV library stands for Open Computer Vision
Library. It was first released in 1999 by Intel. It has since been VII.RESULT
updated with further changes to strive for real-time computer
vision. This library was created using C and C+ programming
languages. It runs smoothly on both Windows and Linux
operating systems.This library works with a variety of
programming languages, including Python, MATLAB, Ruby,
and others. Image processing i.e. shape and colour
detectioncan be done quickly and easily with Numpy and
Python.OpenCV is a open-source computer vision library for
image processing, machine learning, and computer vision.
Python, C++, JAVA and other programming languages are
supported by OpenCV. It can identify objects, faces etc. by
processing images and videos.
Fig. Masking of objects
2.Delta PLC Software: Masking is an image processing technique in which a small
‘image piece' is defined and used to modify a larger image.
 ISP Soft V3.12.
masking is the process which includes many types of image
 Commgr V1.12 simulator.
processing, such as edge detection, motion detection, and
noise reduction, depend on method of masking.
3. Modbus:
 The objects are separated into two bins based on their
Modbus is a communication protocol for transmitting colour and shape.
operational data in industries (OD). Modbus supports both  Using a pneumatic actuator, objects that aren't the
serial (RTU) and Ethernet (TCP/IP) communications. It is right colour or shape are sorted.
based on a Client-Server architecture, with the ‘Master' device
acting as the Server and the ‘Slave' device acting as the Client.
When the Modbus Slave receives a request from the Modbus
VIII. CONCLUSION
Master, it transfers data. You need to send request in the
Modbus.
The object sorting method can be effectively implemented in
medium and large-scale industries for batch sorting of objects
V ADVANTAGES
based on different colours and shapes.
The following are some of the advantages of an automated
In this system, colour and shape information was converted
sorting system: into a series of commands that were sent to the handling
 High accuracy is maintained. device's driving unit. With the help of a computer vision
programme, the machine was able to complete an effective
 Reduction in the number of labourers required. sorting process.
 System takes very less time for sorting.
 Possibility of getting defective objects is very less.
 Customer satisfaction is more.

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 05 Issue: 05 | May - 2021 ISSN: 2582-3930

IX. REFERENCES

[1]Bhagyshree P Kulkarni, Monika A Satpute,

Prof. S A Soundattikar,“IMAGE PROCESSING
AND PLC BASED AUTOMATED BISCUIT
SORTING SYSTEM”, International Conference
On Recent Innovations In Engineering and
Management,2016.

[2]Ms. Supriya D. Garud, Prof. J. S. Shaikh,

“IMAGE PROCESSING BASED GRAIN
SORTING SYSTEM USING RASPBERRY-
PI”, International journal of Electrical and
Electronics Engineers, 2017.

[3]Akshay Warpe, Snehal Marne, Mansi Morye,

Dr. Manisha Jadhav ,“AUTOMATIC
DETECTION AND SORTING OF
PRODUCTS”, International Journal Of
Innovations In Engineering Research And
Technology,2017

[4]Raghav Puri, Archit Gupta, Manas Sikri,

“CONTOUR, SHAPE, AND COLOUR
DETECTION USING OPENCV-PYTHON”,
International Journal Of Advances In Electronics
And Computer Science,2018

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