COLOR SORTING ROBOTIC ARM IN A PICK & PLACE MECHANISM

An Undergraduate Thesis

Presented to
The Faculty of the Electronics Engineering Program
University of Mindanao

In Partial Fulfillment
Of the Requirements for the Degree
Bachelor of Science in ElectronicsEngineering

By
Flete, Ed Michael O.
Generoso, Rolando T.
Bastasa, Robert Francis R.
October 2016

I.

Introduction
In the past century manufacturing industries are trying to hire a lot of

workers to manufacture their products but human processing can cause many
challenges in maintaining product quality. An employee who has been
requiring motion over a long duration, performing a repetitive inspection task
may eventually fail to recognize a defective product and also resulting in
possible ergonomic issues (Batchchu, 2015). More chaotic and dangerous tasks
have fallen to humans for instance, in the field of industry; wherein one needs
to sort a majority of items in short time. Furthermore, the weight is more
prominent than what a human can convey (Iovino, 2011). If these always
happen, production is not efficient, and it causes big problem to the company.
Industries today are approaching to use a color sensor to fulfill their
needs for a higher production and precise quality of their products. They are
using some of the following features, like Color and Shape to distinguish
between objects, sorting, recognizing and tracking (kamthe, 2015). Innovations
of color sensors with larger amounts of reconciliation are getting accessible,
taking into account more financially savvy arrangements. Color sensors have a
many applications nowadays that industrial companies are using, for example,
color screen alignment, shading printers and plotters, paints, materials,
beautifiers fabricate and therapeutic applications, for instance, blood
diagnostics, pee investigation, and dental coordinating.

In this research project, an application will be developed using the color

sensor, microcontroller, and servo motors. One of the applications of color
sensor is color by sorting and color coordinating (Aji Joy, 2014). Also, this
project aims to pick the colored objects and placeit in its respective container

II.

Objectives of the Study

The study aimed to develop an automated robotic arm using color

sensor to pick and place the color of the object to its respective location. It
specifically sought to achieve the following objectives:
1. Design a control system for a robotic arm that can sort 1x1
cube colored objects.
2. Develop the program that can identify ten (10) different colors
(red, green, blue, yellow, brown, silver, violet, pink, orange
and gray) from the object.
3. Conduct a function test.
a. Perform a trial tests.
b. Test the accuracy of the device.
4. Present the total cost of the device.

III.

Conceptual Framework
In figure 1. The conceptual framework shows the concept of this

study and it explains on how the proponents address the objectives. In this
figure the proponents build the control system and make the program for
robotic arm to accomplish the objectives of the study. Appendix A shows the
whole source code of the devices.

Input

bv

Manual
Colored
Objects
Sorting
Colors

Process

Building
Control
System for
Robotic Arm
Making
Program For
color

Output
Color SorterPick
and Place
Robotic Arm

Figure 1.Conceptual Framework

IV.

Significance of the Study

The handling repetitive task in the working place of the industries

may cause ergonomic issues to the workers which result to low production
quality of the products in the sectors. Today, as the technology increases,
automation using robots is one of the inventions that are very popular in
performing a wide variety of task. The most common robot application are
material handling, picking, palletizing, packaging, etc.
The main objective of the project is to make a robotic arm
which can sort the particular color of the object and place it in its respective
containers. Color Sorting Robotic Arm in a Pick and Place Mechanism will
increase and improve the product quality while having the lower production
cost in the industrial companies. Also, it will help to perform tasks that are
complicated, dangerous and in the hazardous area. Most of all, with the support
of this project the job will make faster and easier.

V.

Target Beneficiaries
The Researchers conduct this kind of study to help/benefit the

following:
The Researchers. This study will help the researchers to enhance
their knowledge about the robotic arm and also about the color sensor.
The Industrial Companies. In this kind of research, it will help
the industrial companies to improve their productivity and to make their work
faster and easier.
The Students. This study will give ideas to the students on how
to interface the color sensor, servo motors and microcontroller to the robotic
arm.
The Workers. This study will give comfort to the workers to
make their jobs easier while avoiding ergonomic issues.

VI.

Review of Related Literature

In this chapter, the articles related to the research project are well

presented. The components or the materials being used in this research are also
discussed thoroughly.

Color Sensor Selection

Color sensors can capture a particular color. It often uses RGB (red,
green, blue) concepts. Each color is emitted in pulses from the sensor of the
transmitters, and its receiver evaluates the pulsed light reflected from the target.
Color sensors are mostly single-channel which means it can only sense one
color. But there are also instances that allow sensing multiple color
identification. Color sensors work on the RGB principle but mechanically
select the ideal color source for an application based on the background color
and the target (Shaum, 2007)
Color Theory
Color theory is based on the existence of three primary colors namely
red, green and blue, mixing this colors will result in all other colors. These
colors, called as a primary colors varies according to their application (Rutter,
2006). The perception of a person is quite different from the understanding in
someone else this is due to the cultural background and others are due to
personal preference. In philosophy, color is a science in itself. Learning on how
colors affect different persons, either as a group or individually may build their
careers, and theres a lot to it. Like as simple as changing the exact type or kind
of a color can inspire entirely different emotions. Cultural differences mean that
something that is relating the culture in one country and the other (Cameron
Chapman, 2010).

Servo Motor

Servo motor is a device that was having a small size with an output
shaft. It works on a programmable code signal from the microcontroller. The
shaft is intended to be placed into a particular angular position using sending
the code signal. The servo motor will remain in the position while waiting for
the coded signal exists on the input line (Vishnu and Kulkarni, 2013). Servo
motors have many different kinds of practical uses, for example, they are used
in radio controlled airplanes to place control surfaces such as elevators and
rudders. Some of the most common applications of servo motors also include
radio controlled cars, robots, etc. (Dadhwal, 2010). There is an encoder
mounted in most of the servo motors. However, it is also possible to use
feedback device to command a motor and also with the utilization of the
extrinsic encoder. When applying an external encoder, it is very critical that
there will not enough supply of the allowable amount of assent between the
motor and the encoder. Mainly, the encoder can directly sense if there is any
change in the position of the motor (Galil, J. 2015).
Pick-and-place applications
Designing a wide-ranging automation for high-speed pick and place
applications is one of a different responsibility handled by motion engineers.
As robotic systems turn out to be more complicated and manufacturing rates
rapidly increasing. Engineering designers should continue with the modern
equipment in designing the entire design of the system and must take it into
account the hazard in specifying optimal design (Richards, 2011). In the
manufacturing industries of robotic application, the word robot is defined as a

gadget that naturally performs repetitive and challenging tasks. Although there
is no scarcity of complication, distribution and also repetition in warehousing,
automated robots should have to develop an innovative ability to handle the
challenges of those unstructured places (Bond, 2014).
Microcontroller
The microcontrollers are embedded designs in our way of life which are
found in most of the devices. This method produces a very robust system that
allows interconnection to our electronic devices which gives the unlimited
variety of applications (Lopez, 2011).The demand of microcontrollers
nowadays is continuously increasing. As operated by the developments in the
semiconductor industry. It is an embedded design, which is widely used in any
devices and it is connected to a battery or power supply. Most of the Electronic
gadgets in our household is composed of at least 50 embedded
microcontroller/s in them (Walsh and Nooshabadi, 2008). The computer is
intended to execute the overall job entirely on a single device like you can use
a computer to run software to perform calculations or to access the internet
through using a browser or also you can use a computer to save your files.
Microcontrollers are intended only to carry out a particular task, for, e.g.,
switching ON automatically the lights in your house during sunset and again
turning it OFF when the sun rises (Daga, 2008).

Gripper
A small-scale flexure-based gripper was intended for handling tasks
needing force control and accuracy position. The gripper provides efficiency as
one the degree-of-freedom in the robotic arm manipulators. It is a mechanical
design for picking an individual object. Information is well presented about the
characteristics of the gripper performance under both force control and
positioning. Also, followed by a discussion of the limitations and attributes of
the design (Goldfarb and Celanovic, 1999). One of the tasks of Robotic
manipulators is the holding and gripping of the objects. The improvement of
grippers nowadays can pick-up the different kinds of shape of the object.
Modern designs are now introducing software and hardware interfaces, unlike
the old models that are based on the human hand. However, these include a
significant amount of force to handle the object carefully without crashing it
and also the proper weight to carry the object (Meiron, 2010).

VII.

Scope and Delimitation

The limitation of this project is that the robotic arm can only

perform the following: First, the robotic arm can carry only below 1000
milligrams that have a size of 1x1 colored object (square/cube). Second, it
cannot pick a large size object and also cannot pick the different shape of
objects like circles, triangles, etc. Third, it cannot pick mixed color object.
Lastly, it is limited to ten (10) different colors (red, green, blue, yellow, brown,
silver, violet, pink, orange, gray) sensing only.

VIII. Methods
Included in this chapter are the research design, research procedure, and
statistical treatment of the data.

Research design
The Color-Sorting Robotic Arm in a Pick and Place Mechanism was a
capstone study. Capstone study is a culminating experience in which students
are expected to integrate particular studies with the major, and widen, review,
and apply the knowledge that gained by the students in their major (Wagenaar,
1993). It is viewed as a "final, mastery experience" (Davis, 1993). It focuses on
the ways of knowing in the discipline and addresses the types of questions and
issues faced by the discipline. It should encourage students to integrate facets
of their area of concentration with important concepts from related disciplines.
The proposed study was based on the different standard which given by
ISO and IEEE. The proposed study based on the ISO 14539:2000 and IEEE
10.1109/TAEE. 2012.6235428-2012 standard for availability of chosen
material and production cost discuss the functionalities of grasp-type gripper
and the low-cost robot manipulator. The standard is the basis of the study for
choosing the affordable material.

Research Procedure
The following are the procedures and activities performed by the
researchers for the completion of this research project.

10

The proponents had searched all the necessary information related to the
research project and gathered data to analyze carefully for the better
understanding in making this project after the data gathered, theproponentsstart
planned the designs thoroughly based on its desired purpose. It includes the
circuitry of the whole device and also on how the robotic arm should work.
After canvassing and identifying the right materials should be used in
this research project, the proponents bought the materials specifically; servo
motor, gripper, microcontroller and other important materials for building the
design. The proponents first build the robotic arm using acrylic glass according
to the design then start building the control system based on the schematic
diagram of the entire device and make program to accomplish the objective.
The color sensor which serves as the input to the system then fed to the
microcontroller, then the microcontroller will evaluate these input by
performing the program created and transmit the data going to the servo motors
to rotate its specific task. The system used the Arduino Uno microcontroller
which supports the entire program of this study.
After building the whole device, the researchers conducted several test
to test its functionality like identifying the exact color of the object and sorting
of objects. The data gathered from the device shows in the color sorting robotic
arm in a pick and place mechanism function test table were explained.The
researchers performed troubleshooting by calibrating the color sensor, revising
the microcontroller program and checking the connectivity of the entire device.

11

IX.

Findings of the Study

In this area, the robotic arm structure, research constraints, trade

of analysis, schematic diagrams, designs concepts used and the results for the
color sorting robotic arm in a pick and place mechanism were documented.
Also, this section contains the function test results.

Robotic Arm Structure

In this part, the robotic arm is controlled using four servo motors
namely: MG995 servo whose degree of rotation is controlled by our
microcontroller which is the Arduino Uno. In terms of the structure of the
robotic arm, numerous degree of rotation for the servo motor were assigned
specifically to carry out the tasks.
The robotic arm is made of acrylic glass. The acrylic glass were cut
according to size of the MG995 servo motor so that it will fit-in in to the
robotic arm. Two servo motors were attached in the left side (elbow) and right
side (shoulder) of the robotic arm. 1 servo motor was located at the bottom of
the robot which was at base in order to rotate 360 degrees and the other 1
servomotor attached in the gripper to pick the object.

Figure 2. Robotic Arm Structure

For Design 1

12

Figure 3 is the Design Concept, the Color Sensor is the indicator of our
device. Once the color sensor distinguish/identify the color of the object, the
Microcontroller will start processing the signal came from the color sensor,
then themicrocontroller will send signal to the servo motorto rotate and
perform to its specific task.

Input

Process

Output
Robotic Arm

Color Sensor

Microcontroller

Figure 3.Design Concept for Design 1

For design 1: This design is limited only for RGB (red, green, blue)
sensing only for a pick and place application. Four (Zebra ZS F135) micro
servo were used. It was attached to our robotic arm in the base, elbow, wrist
and the gripper. Therotation of the robotic arm cannot rotate 360 degrees and
also the movement are very limited. This four servo motors were monitored

13

always because it is very sensitive in terms of power supply so it must be

regulated. The images in the next page are the Design 1 of the project

Figure 4. Images in 2D (Design 1)

Figure 5. Images in 3D (Design 1)

For Design 2
Figure 6 is the Design concept for the Design 2, the Color Sensor was
the indicator of our device. Once the color sensor distinguish/identify the color

14

of the object, the Microcontroller will start processing the signal came from the
color sensor, then the microcontroller will send signal to the servo motor to
rotate and perform to its specific task.

Input Process

Output
Robotic Arm

Color sensor
Microcontrolle
r

Figure 6.Design Concept for Design 2

For design 2: This design is limited only for (red, green, blue, orange,
yellow, gray, pink, brown, silver and violet) sensing only for a pick and place
application. Four (MG995) servo motor were used. It was attached to our
robotic arm in the base, elbow, wrist and the gripper.
The rotation of the robotic arm can rotate 360 degrees and also the
movement are wider than the 1st design. This four servo motors (MG995) are
more powerful than the micro servos (Zebra ZS F135) that being used in the 1 st
design. The design 2 has been chosen for it fits the objectives of the
entireresearch project. The images in the next page were the design 2 of the
project.

15

Figure 7. Images in 3D (Design 2)

Research Constraint

Economic.Color Sorting Robotic Arm in a Pick and Place Mechanism

can be manufactured at a low cost and also due to our allotted budget in
assembling the whole project.
Manufacturability.Color Sorting Robotic Arm in a Pick and Place
Mechanism has composed of materials that is very hard to find in this country
which adds up the difficulty in assembling this research project. The advantage
of this study is that the device can be modified and assembled in the
availability of the materials that were used.

16

Sustainability. Color Sorting Robotic Arm in a Pick and Place

Mechanism was built while considering the durability of the materials that
were used so that it can sustained the specific task of the device.

1. SUSTINABILTY
PARAMETERS
Performance under
heavy usage

STANDARDS
ISO 20121:2012 Event

DESCRIPTION
Specifies requirements for

sustainability an

event

sustainability

management systems -- management

Requirements

system

for

with any type of event or event-

guidance for use

related

activity,

provides

guidance

conforming

to

and
on
those

requirements.
Expected lifespan

26702-2007-ISO/IEC
Standard

for

Standards for Application

Systems and Management of the

Engineering

Systems

Engineering

Process

Maintenance

IEEE 333-1980

Guide for In-Service Use,

Care,
Testing.

2. MANUFACTURABILITY

Maintenance

and

17

3. ECONOMIC

18

PARAMETERS

STANDARDS

DESCRIPTION

Production Cost

IEEE 10.1109/ TAEE.

IEEE Standard for A

2012.6235428 - 2012

low-cost robot
manipulator for
education

Note: A detailed description of the standards and references are presented in the
succeeding pages

MANUFACTURABILITY
1. Availability of Materials
A. IEEE10.1109/ISATP.1999.782936 2002 presents a modular
computer system for manufacturability analysis of robot-made
assemblies. In order to say if a specific design can be assembled in a
specific robotic cell, designers must answer a number of questions
about sequencing, stability, fixturing, grasping, and motion planning
and tool accessibility.
Although several tools have been developed to compute some of the
answers needed by designers. They have been developed in an isolated
fashion making it hard to integrate their results. Each tool uses its own
object models (which highlight some particular analysis features), sets
of constraints, scale factors, and base units (inches, mm, etc.) leading

19

to incompatibility problems when designers need to chain them, i.e. to

use the output from one tool as the input for another one.
B. ISO 14539 is one of a series of standards dealing with the
requirements of manipulating industrial robots. Other documents cover
such topics as terminology, general characteristics, coordinate systems,
performance criteria and related test methods, safety, mechanical
interfaces and graphical user interfaces for programming. It is noted
that these standards are interrelated and also related to other
International Standards.
Object handling with manipulating industrial robots is steadily
diversifying as robots proliferate in automated manufacturing. This
standard provides the vocabulary for understanding and planning of
object handling and presentation of characteristics of grasp-type
grippers.
Successful object handling is achieved with the cooperation of both
robots and end effectors. In some cases robot arms/wrists play major
roles in positioning objects. In some other cases, however, end
effectors with adaptively controlled fingers can perform flexible object
handling.
Definition:
4.1.2.1Grasp-type gripper. gripper that handles an object with finger(s)
C. IEEE2700-2014- Sensor
A common framework for sensor performance specification terminology,
units, conditions and limits is provided. Specifically, the accelerometer,
magnetometer,

gyrometer/gyroscope,

barometer/pressure

sensors,

20

hygrometer/humidity sensors, temperature sensors, ambient light sensors, and

proximity sensors.
2. Complexity of the Device
The International Standards ISO 9283 and ISO 9946 were published in
1990 and 1991 in order to meet the needs of industries. For the purpose of
supplementing these standards some amendments are being investigated for
real applications.
It is important to clarify the kind and performance level of existing
measurement systems applicable to robots in relation to ISO 9283 and
establishing additional standards or reports.
This Technical Report contains an attempt to classify the measurement
techniques and methods applicable to the robot characteristics testing, and
describes the principles of operation and accuracies of the current state-of-theart, and as much as possible, currently available measurement systems.
3. Safety Requirements for Industrial robots
A. ISO 10218-1:2011.Robots and robotic devices - Safety requirements
for industrial robots
Part 1: Robots. This standardspecifies requirements and guidelines
for the inherent safe design, protective measures and information for
the use of industrial robots. It describes basic hazards associated with
robots and provides requirements to eliminate, or adequately reduce
the risks associated with these hazards.
ISO 10218-1:2011 does not address the robot as a complete machine.
Noise emission is generally not considered a significant hazard of the

21

robot alone, and consequently noise is excluded from the scope of

ISO 10218-1:2011.
ISO 10218-1:2011 does not apply to non-industrial robots, although
the safety principles established in ISO 10218 can be utilized for
these other robots.
B. ISO 10218-2:2011. Robots and robotic devices -- Safety
requirements for industrial robots
Part 2: Robot systems and integration. This standard specifies safety
requirements for the integration of industrial robots and industrial
robot systems as defined in ISO 10218-1, and industrial robot cell(s).
The integration includes the following:
a. the design, manufacturing, installation, operation, maintenance and
decommissioning of the industrial robot system or cell;
b. necessary information for the design, manufacturing, installation,
operation, maintenance and decommissioning of the industrial robot
system or cell;
c. component devices of the industrial robot system or cell.
ISO 10218-2:2011 describes the basic hazards and hazardous
situations identified with these systems, and provides requirements to
eliminate or adequately reduce the risks associated with these hazards.
ISO 10218-2:2011 also specifies requirements for the industrial robot
system as part of an integrated manufacturing system. ISO 102182:2011 does not deal specifically with hazards associated with

22

processes (e.g. laser radiation, ejected chips, welding smoke). Other

standards can be applicable to these process hazards.

ECONOMIC
Production Cost
IEEE 10.1109/ TAEE. 2012.6235428 2012. In general, professors that
are teaching industrial robotics for the first time wonder how to motivate the
students during the course. Robotics is a relatively young field of modern
technology that crosses traditional engineering boundaries. Understanding the
complexity of robots and their application requires knowledge of electrical
engineering, mechanical engineering systems and industrial engineering,
computer science, economics, and mathematics.
Due to the multidisciplinary nature of the field, robotic education is
most effective when theoretical concepts are coupled with tangible
experiments. Making this connection effective requires a pragmatic way of
applying the traditional robotic material to exciting laboratory exercises.

SUSTAINABILITY
1. Performance under Heavy Duty
A. ISO 20121:2012. This International Standard specifies the
requirements of an event sustainability management system to improve the
sustainability of events. It is applicable to all types and sizes of organizations
involved in the design and delivery of events and accommodates diverse

23

geographical, cultural and social conditions. At the same time it requires

organizations to recognize their relationship with and impact on society and
society's expectations of events.
A management system standard challenges an organization to improve
its process and thinking to lead to continual performance improvement and
allows the organization the flexibility to be more creative about the delivery of
event-related activities without detracting from the aim of the event. A
management system standard is not a checklist or a reporting framework or a
method of evaluating event sustainability performance.
This International Standard is intended to be applied flexibly and will
allow organizations that have not formally addressed sustainable development
to start to implement an event sustainability management system.
Organizations with existing management systems will be able to integrate the
requirements of this International Standard into their existing systems. All
organizations will benefit from the process of continual improvement over
time.
The complexity of the system and the extent of documentation and the
resources devoted to it will be proportional to its defined scope, the size of the
organization and the nature of the organization's activities, products and
services. This is particularly the case for small and medium sized enterprises.
The success of the system depends on commitment from all levels and
functions, especially from top management. In addition, in order for such a
management system to be successful, it needs to be flexible and integrated

24

within the event management process and not just regarded as a component to
be added on. For maximum effectiveness, its influence needs to extend
throughout the supply chain, as well as the identified stakeholders.

2. Expected lifespan
ISO/IEC

Standard

for

Systems

Engineering-Application

and

Management of the Systems Engineering Process. The interdisciplinary tasks,

which are required throughout a system's life cycle to transform customer
needs, requirements, and constraints into a system solution, are defined. In
addition, the requirements for the systems engineering process and its
application throughout the product life cycle are specified. The focus of this
standard is on engineering activities necessary to guide product development
while ensuring that the product is properly designed to make it affordable to
produce, own, operate, maintain, and eventually to dispose of, without undue
risk to health or the environment.

3. Maintenance
IEEE 333-1980. The purpose of this standard is to provide guidelines for

the proper application of electrical equipment to packaging machinery. These

guidelines will promote: (1) Safety to personnel and equipment, including the
reduction of fire and accident hazard (2) Uninterrupted production (3) Long life
and low maintenance cost This standard provides minimum guidelines and is

25

not intended to limit or inhibit advancement in the areas of electrical or

mechanical engineering.
Table 1. Trade-off Analysis

Trade-off Analysis
In table 1 above the researcher present the data of choosing the best
design suitable for the study, considering the manufacturability, economic, and
sustainability constraints, the researchers was able to come up with a
conclusion that such design is the best option. The Pugh Matrix used by

26

researcher to determine the best design. Pugh matrix is the way of assessing
different design against each other leading to which best meet the criteria
(Burge, 2009). Analytic Hierarchy Process (AHP)is used in determining the
weight of each criteria.The AHP creates a weight for every criteria as indicated
by the decision makers pairwise examinations of the criterion. The higher the
weight, the more significant the criterion. For the fixed criterion, the decision
makersassigned AHP for each criterion based on the criteria that were listed.
Lastly, the AHP merges the weight criteria and choice scores in determining a
global score for each possible choices and consequent ranking (Saaty, 2008)
.See appendix D for the Pugh Matrix solutions.

Color Sensor

Microcontroller

Servo Drive
&motor base

Servo Drive
&motor

Servo Drive
&motor Wrist

Servo Drive
&motor

Figure 8. Block Diagram of the Entire System

The figure above shows a block diagram of the entire system. Different
procedures were be used for detection of the colored object. For the sample test
of this research project the researchers used the color sensor (TCS3200) for the
detection of the 1x1 colored object. Since, the color sensor was being used
without much processing of the input data came from the colored object, so the

27

sensing of the colored object was completed at a faster rate. After detecting the
colored object, the color sensor will sent a signal to the microcontroller. The
main task of the microcontroller was to control the movement of the servo
motors that were connected to the robotic arm and to execute its specific task.

The Robotic arm

picks and place to
corresponding
container

Start

Detect the RGB color of the object

Is the color detected equal to color

inserted?

YES

NO
End

Figure 9. Flow Chart of the Control System

The figure 8 above shows the device will work normally. The
functionality of the entire system was achieved through giving the desired
amount of power required to fully functional the Color Sensor (TCS3200), a
microcontroller (Arduino Uno) and the four Servo Motors (MG995). The
process was obtained by the following: 1st through sensing the specific range
intensity of the color came from the 1x1 colored object using the color sensor.
2nd the output signal of the color sensor will be processed by the

28

microcontroller which is the Arduino Uno and lastly, after the microcontroller
knows the exact intensity of the colored object then that is the time that the
microcontroller will send the output signal through the four servo motors
(MG995) to do its specific task.

Servo
Servo

Inserted object
Color

Servo

Servo
Servo

Arduino

Figure 10. Functional Block Diagram for the Control System of the Whole
Project

Figure 9. For the control of the device, the color sensor will be the input
variable of the device that sent the output signal to the microcontroller which is
the Arduino Uno then the Arduino Uno controlled the four servo motors to do
its specific rotation and its served as the output of our device.
Schematic Design
Figure 10. It shows the schematic diagram of the entire system. The
TCS3200 Color Sensor serves as the input data of the device which identifies

29

the specific color intensity of the 1x1 colored object. The output signal
produced by the sensor will send to the Arduino Uno.
The Arduino Uno is the main controller of the device. It allows the
entire system to perform the exact procedure as programmed by the
proponents. The output signal came from the Arduino will directly go to the
four servo motors to move with its desired position.

Figure 11. Schematic Diagram of the System

Actual device
In Figure 11 is the actual circuitry of the servo motors, power supply
circuit and Arduino Uno. The Arduino is the main controller of the device.

30

Figure
SystemDevice

12.Control

Figure 12. shows the actual colored object that is used in this project. It
has a size of 1x1 with the weight less than 1000 milligrams.
In Figure 13. shows the Actual Device of the study. It composed of color
sensor, control system, ten different colored objects, 10 containers and
especially the robotic arm.

Figure 13. 1x1 Colored ObjectsFigure 14.Actual Device

Function Test
Table 1.This section presented the following function test results of the
device having ten (10) consecutive trials done by the proponents. This was
shown in the table below. Based on the function tests done, the color sensor, the
microcontroller, and servo motors are 100% functional. But during the first and

31

fourth trial, the robotic arm was unable to pick the colored object and unable to
sort to its specific container. It was found out that this error was due to the
excessive movement of the servo motors, since the servo motors can be
programmed through Arduino ide.
The researchers conduct some changes of the source code to achieve the
efficiency of the device for the next trial. The same thing happened on the third
trial but this time the error was discovered in the colored object because as the
researchers painted the 1x1 cube object, some of the sides has different
intensity since the proponents painted the objects manually, not all the sides
have the same intensity of the color as it goes to the color sensor. So the
researchers came up again for the solution of the problem, to calibrate again the
colored objects and adjust the range of the RGB value of the objects so that
during another trial the value of the intensity of the color will fit in to its
specific range value.
Despite of all the errors during the function tests period, the researchers
were able to find solutions to correct the said errors. In the fifth to tenth trials,
the device performed very well without any further errors happened. See the
table 2 below.

32

Table 2. Color Sorting Robotic Arm in a Pick and Place Mechanism

Pre-Function Test Table

Number
of Colored
objects
Detected

Number
of Colored
objects
Picked

Number
of Colored
objects
Sorted

Results

Attempt 1

10 objects

9 objects

9 objects

Failed

Attempt 2

10 objects

10 objects

10 objects

Successful

Attempt 3

8 objects

8 objects

8 objects

Failed

Attempt 4

10 objects

9 objects

9 objects

Failed

Attempt 5

10 objects

10 objects

10 objects

Successful

Attempt 6

10 objects

10 objects

10 objects

Successful

Attempt 7

10 objects

10 objects

10 objects

Successful

Attempt 8

10 objects

10 objects

10 objects

Successful

Attempt 9

10 objects

10 objects

10 objects

Successful

Attempt 10

10 objects

10 objects

10 objects

Successful

All ten colored objects in all attempts were successfully detected by the
color sensor TCS3200 as what really the color of the object was, except on the
third attempt that fails to detect all ten colors because some intensity of the
colors were not calibrated. The base servo was not that accurate for it has
tolerance that makes the robotic arm not to move accurately to its designated
position and it affects the picking of the object and sorting it to its assigned

33

container to fail sometimes. And that results to 3.33% of error rate due to the
failure in attempts 1, 3 and 4
Table 3. Color Sorting Robotic Arm in a Pick and Place Mechanism
Final Function Test Table
Number
of Colored
objects
Detected

Number
of Colored
objects
Picked

Number
of Colored
objects
Sorted

Results

Attempt 1

10 objects

10 objects

9 objects

Successful

Attempt 2

10 objects

10 objects

10 objects

Successful

Attempt 3

10 objects

10 objects

10 objects

Successful

Attempt 4

10 objects

10 objects

10 objects

Successful

Attempt 5

10 objects

10 objects

10 objects

Successful

Attempt 6

10 objects

10 objects

10 objects

Successful

Attempt 7

10 objects

10 objects

10 objects

Successful

Attempt 8

10 objects

10 objects

10 objects

Successful

Attempt 9

10 objects

10 objects

10 objects

Successful

Attempt 10

10 objects

10 objects

10 objects

Successful

For the final function test, the color sensor TCS3200 was calibrated
again that the possible intensity of a single color can be detected. Capacitors
are installed in the servos and also in the base servo to lessen the surge
movement caused by the tolerance. The test has a result of 0% error rate.

34

Move

1
2
3
4
5
6
6.1
6.2
6.3
6.4

Movement/Motor
Default/Power ON
Gripper Open
Left lowered
Right Lowered
Pick the 1x1 object
Left moving up
Right moving up
Move to Correct box
(Red) CW rotation
Move to Correct box
(Green) CW rotation
Move to Correct box
(Blue) CW rotation
Move to Correct box
(Orange) CW rotation

Base
Servo
3
3
3
3
3
3
3
25

Left Servo
140
140
90
90
90
140
140
140

Right
Servo
90
90
90
127
127
127
90
90

Gripper
Servo
128
90
90
90
128
128
128
128

35

140

90

128

50

140

90

128

65

140

90

128

6.5

Move to Correct box

(Brown) CW rotation

80

140

90

128

6.7

Move to Correct box

(Gray) CW rotation
Move to Correct box
(Pink) CW rotation
Move to Correct box
(Yellow) CW rotation

95

140

90

128

110

140

90

128

125

140

90

128

140

140

90

128

155

140

90

128

Move to Correct box

(Silver) CW rotation
Move to Correct box
(Violet) CW rotation
Left lowered

25

90

90

128

8
9

Right lowered
Drop the object

25
25

90
90

127
127

128
90

10
11

Gripper Closed
Left moving up

25
25

90
140

127
127

128
128

12
13

Right moving up
Default

25
3

140
140

90
90

128
128

6.8
6.9

6.10
6.11

Table 4.Degree of Rotation of Different Servo Motors in the Robotic Arm

for Different Operations

35

The researchers assume that the color sensor detects red 1x1 colored
objects. The object should be dropped in the disposable plastic container at the
right side. The rotation of the base servo motor depends on the color of the 1x1
object to be picked up. The degrees of rotation assigned to the base servo,
changes according to the robotic arm position itself above the right container at
which the 1x1 colored objects is to be placed and the object color. Now the
object is to be dropped. After the 1x1 colored object is placed in its specific
position, the robotic arm will return to its default position to pick and place the
next object. The MG995 base servo motor rotates Clock Wise when going to its
respective container and Counter Clock Wise rotation when going to its default
position.

Costing
The total cost of the entire project was 11,216.00. The corresponding
materials used in the color sorting robotic arm in a pick and place mechanism is
shown in table 3 below.

36

Table5. Cost of Materials

Quantity

Equipments

Unit Price

Amount

MG995 Servo
Motor
3/16 Clear Plastic
Plywood
Acrylic
Drill Bits
Acrylic Cutter
Bolt and Knots
Lotus Paint
Paint Thinner
Paint Brush
Masking Tape
Glue (888)
Gripper
Soldering Lead
Header Pins
Crown Jack
Chassis
Color Sensor
PCB(4x4)
Ferric Chloride

700

2800

600
315
350
515/set
279
4
20
29
18
15
85
479
10/m
40
20

600
315
350
515
279
200
220
29
18
60
170
479
30
80
20

350
35
25

350
35
25

70/bundle
6

210
60

50
20/m
650
70
22
600

50
40
650
70
66
600

1
1
1
5pcs/set
1
50
11
1
1
4
2
1
3m
2
1
1
1
1
3
10
1
2m
1
1
3
2

Jumper Wires
Disposable
Container
Spring
UTP wires
Arduino Uno
Jigsaw Bit
Caster Wheel
Power Supply
Miscellaneous

2,895

TOTAL

11,216

37

IX. Conclusion

Based on the series of trial and testing done by the researchers, the
research study for the color sorting robotic arm in a pick and place mechanism
had been effectively accomplished and well-functioning. The researchers
concluded that:

1.

The design of the project and also the assembly of the circuitry for the

whole system of this research study is able to perform its specific functions
where it could sense the 10 different colored objects (red, green, blue, orange,
yellow, brown, pink, silver, gray and violet) having a size of 1x1 and a weight
less than 1000 grams through the color sensor (TCS3200) used. The robotic
arm can able to pick the colored object and also can place it in its respective
container. For the color sensor, microcontroller and servo motors to
successfully functional it must be supplied with sufficient power.

2.

The programmed codes ware able to support the entire operation of the

color sorting robotic arm pick and place mechanism for the whole system of
our research study with the help of Arduino Uno.

3.

The device is tested many times during the function tests. The researchers

developed the program codes and the structural design of the robotic arm to

38

fulfill the objectives of the stud and, to achieve the functionality and stability of
the device.
4.

The total cost is presented based on the materials used in the whole device

of this research study.

The availability of the chosen materials is very important in building the

project. Also, having the enough knowledge to program the entire system and
sufficient power of the device, the system will function very well. Therefore,
the device can sort the specific colored object, pick and place it in its respective
container.

X. Recommendation
To further improve the whole system of this device, the following
recommendations were suggested:
1.

For the development of our device, we recommend the future

researchers to use powerful servo motors to carry heavy objects.

2.

Can use image verification to identify the specific image of the

object.
3.

For the carrying of the object, we recommend using more powerful

gripper to pick different kinds of object.

4.

For the automation of the colored object, we recommend using

conveyor.

39

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