A

PROJECT REPORT
ON

Robotic Arm-Based Object Sorting System

Submitted in the partial fulfillment of the requirement for the award of the diploma

in

AUTOMATION & ROBOTICS ENGINEERING

Submitted by,

“Roll No.: 12 Rohan Gangaram Kokatare”

“Roll No.: 03 Saurabh Bachchalal Yadav”
“Roll No.: 22 Aryan Jaiprakash Tiwari”
“Roll No.: 11 Utkarsh Pravin Chauhan”

UNDER THE GUIDANCE OF

Mr. KISHOR FARDE

DEPARTMENT OF AUTOMATION & ROBOTICS ENGINEERING

SHIVAJIRAO. S. JONDHLE, POLYTECHNIC

ASANGAON
[2024-2025]
 Vighnaharata Trust’s

SHIVAJIRAO S. JONDHLE POLYTECHNIC, ASANGAON

Institute Code: 0935
(Affiliated to Maharashtra State Board of Technical Education,
Approved by AICTE)

Department of Automation & Robotics Engineering

2024-2025

CERTIFICATE

The project report entitled “Robotic arm with color sorting”

submitted by MR. ROHAN KOKATARE are approved for the Diploma in
Automation & Robotics Engineering from Maharashtra State Board of Technical
Education, Mumbai.

Mr. Kishor Farde Mr. Kishor Farde. Dr. Anwesh K. Virkunk

Guide Head of Department Principal

External Examiner Sign

Date:
Place:
 Vighnaharata Trust’s

SHIVAJIRAO S. JONDHLE POLYTECHNIC, ASANGAON

Institute Code: 0935
(Affiliated to Maharashtra State Board of Technical Education,
Approved by AICTE)

Department of Automation & Robotics Engineering

2024-2025

CERTIFICATE

The project report entitled “Robotic arm with color sorting”

submitted by MR. SAURABH YADAV are approved for the Diploma in Automation
& Robotics Engineering from Maharashtra State Board of Technical Education,
Mumbai.

Mr. Kishor Farde Mr. Kishor Farde. Dr. Anwesh K. Virkunk

Guide Head of Department Principal

External Examiner Sign

Date:
Place:
 Vighnaharata Trust’s

SHIVAJIRAO S. JONDHLE POLYTECHNIC, ASANGAON

Institute Code: 0935
(Affiliated to Maharashtra State Board of Technical Education,
Approved by AICTE)

Department of Automation & Robotics Engineering

2024-2025

CERTIFICATE

The project report entitled “Robotic arm with color sorting”

submitted by MR. UTKARSH CHAVAN are approved for the Diploma in
Automation & Robotics Engineering from Maharashtra State Board of Technical
Education, Mumbai.

Mr. Kishor Farde Mr. Kishor Farde. Dr. Anwesh K. Virkunk

Guide Head of Department Principal

External Examiner Sign

Date:
Place:
 Vighnaharata Trust’s

SHIVAJIRAO S. JONDHLE POLYTECHNIC, ASANGAON

Institute Code: 0935
(Affiliated to Maharashtra State Board of Technical Education,
Approved by AICTE)

Department of Automation & Robotics Engineering

2024-2025

CERTIFICATE

The project report entitled “Robotic arm with color sorting”

submitted by MR. ARYAN TIWARI are approved for the Diploma in Automation &
Robotics Engineering from Maharashtra State Board of Technical Education,
Mumbai.

Mr. Kishor Farde Mr. Kishor Farde. Dr. Anwesh K. Virkunk

Guide Head of Department Principal

External Examiner Sign

Date:
Place:
 ACKNOWLEDGEMENT

It gives us great pleasure to submit this project report on “Robotic Arm-Based Object Sorting
System”. We express our sincere thanks to our guide, Mr. Kishor Farde, for his invaluable
guidance, timely suggestions, and constant support throughout this work.

We are deeply grateful to the staff members of the Automation & Robotics Engineering
Department for their persistent inspection and inspiration. We also extend our heartfelt thanks to
our Principal, Dr. Anwesh K. Virkunk, who has been a constant source of motivation to
complete this project successfully.

Name of Student:
Rohan Gangaram Kokatare
Saurabh Bachchalal Yadav
Aryan Jai Prakash Tiwari
Utkarsh Pravin Chavan
 ABSTRACT NO: 1

ABSTRACT:

This project presents the design and implementation of an automated color-sorting robotic
arm system integrated with a conveyor belt, controlled by an ESP32 microcontroller and
remotely operated via an Arduino Uno with ESP-01. The system employs a TCS3200 color
sensor for accurate color detection and an IR sensor for object presence detection, making it
suitable for industrial applications such as manufacturing, packaging, and recycling. The
ESP32 processes real-time data and coordinates a 4-DOF robotic arm’s servo motors, driven
by a PCA9685 servo driver, to pick and place objects into color-coded bins.

The system features dual communication modes—UART (wired) and ESP-NOW (WiFi)—
with a preference for UART when available at power-on, switching to WiFi if UART is not
detected. A 3x5 keypad on the remote allows manual control, recording, and playback of arm
movements, while a 20x4 LCD with I2C displays system status and sorted object counts. The
conveyor, powered by an MG996R servo, transports objects to the detection zone. The
system includes robust error handling: if communication breaks during operation, it holds the
last position and attempts reconnection, resuming from that state upon success. This enhances
reliability and prevents system failures due to connectivity issues. Future enhancements could
include machine learning for adaptive sorting and advanced vision systems for broader object
recognition.
 INTRODUCTION
The Robotic Arm-Based Object Sorting System integrates a 4-DOF robotic arm, a conveyor
belt, and advanced sensors controlled by an ESP32 microcontroller, with a remote interface
powered by an Arduino Uno and ESP-01 module. The system’s primary function is to sort
objects by color, utilizing a TCS3200 color sensor for precise detection and an IR sensor to
identify object presence on the conveyor. The ESP32 processes sensor data in real-time,
directing the robotic arm—equipped with high-torque MG995 and MG90S servos via a
PCA9685 driver—to pick and place objects into designated bins.

The remote control unit features a 3x5 keypad for manual operation, menu navigation, and
recording/playback of arm movements, alongside a 20x4 LCD for real-time feedback.
Communication between the remote and main controller supports both UART (wired) and
ESP-NOW (WiFi) modes, prioritizing UART at power-on for reliability, with automatic
fallback to WiFi if UART is unavailable. This dual-mode setup ensures flexibility in
deployment. If communication fails during operation, the system holds its last position,
attempts reconnection, and resumes seamlessly upon re-establishment, enhancing operational
robustness.

Designed for cost-effectiveness and compactness, this system is ideal for industrial
environments with space and budget constraints. Its modular design allows scalability, such
as adding more bins or enhancing sensor capabilities, making it a versatile solution for high-
throughput sorting in manufacturing, packaging, and recycling applications.
Resources Used:
Qty
Sr.No Name of Resource Specifications

4-DOF, made of PLA filament with 1

1 Robotic Arm servo-controlled gripper for sorting
objects

2 ESP32 ESP32 Microcontroller: Controls arm,

conveyor, and sensors with WiFi/UART

3 Arduino Uno with ESP-01 Remote control unit with ESP-01 for
UART/WiFi communication

16-channel PWM driver for precise

4 PCA9685 Servo Driver
servo control
 3
MG995 Servo Motor High-torque metal gear servos for base,
5
shoulder, elbow movements

Compact metal gear servo for gripper

6 MG90S Servo Motor
control 1

7 MG996R Servo Motor High-torque 360° continuous rotation

servo for conveyor 1

8 IR Sensor Detects objects on the conveyor to

trigger sorting 1
 TCS3200 Color Sensor Detects object color for sorting
9 functionality 2

10 Leather/Rubber Belt Conveyor belt material for smooth

object transport 1

11 LM2596S Buck Converter Step-down converter for stable voltage

to ESP32 and servo driver 3

12 20x4 LCD with I2C Displays sorted object counts and

system status 1
13 3x5 Keypad User interface for remote control and
menu navigation 1

1
14 SPST Push Button
SPST Push Button

15 12V 10A SMPS

Stable power source for entire system

-
16 Wiring and Connectors Various cables and connectors for
electrical connections
Methodology:

1. System Initialization:

- Power on via 12V 10A SMPS.

- ESP32 and Arduino Uno initialize, checking UART availability first. If detected, UART
mode is used; otherwise, WiFi (ESP-NOW) is activated.

- LCD displays “UART Connected” or “WiFi Connected” based on mode.

2. Object Detection:

- IR sensor detects objects on the conveyor, stopping it via MG996R servo for color
scanning.

3. Color Detection:

- TCS3200 sensor reads RGB values, processed by ESP32 to classify color (Red, Green,
Blue) using predefined thresholds.

- Color data is sent to the remote via UART or WiFi.

4. Decision-Making and Sorting:

- Color Matches Preset: ESP32 commands the robotic arm (via PCA9685) to pick and place
the object in the corresponding bin.

- Color Does Not Match: Conveyor resumes to move the object forward.

5. Robotic Arm Operation:

- MG995/MG90S servos execute precise movements based on remote commands or

recorded positions.

6. Display and Count Update:

 - LCD on remote updates sorted object counts and system status (e.g.,
“Stored: X” in Record mode).

7. User Controls (via 3x5 Keypad):

- Run: Starts system at power-on or resumes after pause.

- Pause/Emergency Stop: Halts operations using the emergency stop

button.

- Manual Mode: Adjusts arm angles (Base+/-, Shoulder+/-, Elbow+/-,

Gripper+/-).

- Record Mode: Stores up to 4 arm positions.

- Play Mode: Replays stored positions in a loop.

8. Communication Handling:

- At Power-On: Checks UART first, falls back to WiFi if unavailable.

- During Operation: If communication breaks (UART/WiFi), holds last

position, attempts reconnection, and resumes from last state upon
success.

9. Loop Back:

- System returns to object detection and repeats the cycle.

Applications:

- Manufacturing: Automates color-based component sorting for assembly lines.

- Packaging: Sorts colored products (e.g., bottles) for accurate packaging.

- Recycling: Separates materials by color to enhance recycling efficiency.

- Agriculture: Sorts produce by color for quality control.

- Textiles: Organizes fabrics or garments by color in production or warehousing.

Challenges:

- Real-Time Processing: Ensuring fast sensor-to-arm coordination.

- Lighting Variability: Maintaining TCS3200 accuracy under varying light conditions.

- Communication Reliability: Managing UART/WiFi mode switching and breaks.

- Servo Synchronization: Coordinating conveyor and arm for seamless operation.

- Object Variability: Handling different sizes/shapes for consistent sorting.

FUTURE ENHANCEMENTS:
- Machine Learning: Improve color detection and adapt to environmental changes.

- Camera Systems: Add shape/size recognition beyond color sorting.

- Adaptive Lighting: Integrate LEDs for consistent illumination.

- Expanded Memory: Increase recorded positions for complex sequences.

Conclusion:

The Robotic Arm-Based Object Sorting System, controlled by an ESP32 and remotely
operated via an Arduino Uno with ESP-01, offers a versatile and efficient solution for color-
based sorting. With a TCS3200 color sensor, IR sensor, and a 4-DOF robotic arm driven by
PCA9685, it achieves high accuracy and speed in industrial sorting tasks. The dual
UART/WiFi communication ensures robust connectivity, prioritizing wired reliability while
offering wireless flexibility. Its ability to hold positions during communication breaks and
resume seamlessly enhances system reliability.

Future enhancements like machine learning, advanced vision systems, and optimized lighting
could elevate its capabilities, enabling it to handle more complex sorting tasks and adapt to
diverse environments. This scalable, cost-effective design makes it a valuable asset for
manufacturing, packaging, recycling, and beyond, demonstrating significant potential for
industrial automation advancements.

REFERENCE:

- https://www.espressif.com/en/products/socs/esp32

- https://lastminuteengineers.com/tcs230-tcs3200-color-sensor-arduino-tutorial/

- https://www.adafruit.com/product/815

- https://www.winstar.com.tw/products/character-lcd-display-module/20x4-lcd-display.html

- https://www.researchgate.net/publication/373739005_Color_sorting_robotic_arm

- https://www.arduino.cc/reference/en/libraries/softwareserial/

- https://docs.espressif.com/projects/esp-idf/en/latest/esp32/api-reference/protocols/esp_now.html