1. INTRODUCTION In many situations, Autonomous robots can provide effective solution to dangerous tasks.

In this case, it is desirable to create an autonomous robot that can identify the objects according to their color and relocate them if the objects meet certain criteria. Obviously, when dealing with a large number of objects, this is a very menial task. This is excellent application for a robot of this type. In this case, to keep costs and design complexity low, the robot is designed around the iRobot create platform and uses several different sensors to collect information about the robots environment to allow the robot to react accordingly. Though it is suggested that ancient civilization such as the Egyptians used conveyors in major construction project, the history of the modern conveyor dates back to the late 17th century. These early conveyor systems were typically composed of a belt that travelled over flat wooden bed. The belt was usually made from leather, canvas or rubber and was used for transporting large bulky items. It wasnt until the end of the industrial revolution that conveyors came to be used for a broader range of applications.[9] Color sorting of edge-glued panel parts is an important manufacturing step where color uniformity has an impact on the value of the final products. If performed manually, proper color sorting of edge-glued panel parts is very labor intensive. Also, different people have different perceptions about color uniformity in hardwood panel products. Therefore, uniformity and consistency in edge-glued panel color is very difficult to achieve at production speeds through manual color sorting.[2] The design of the robot arm consists of 4 (four) degrees of freedom with a gripper (clamp) as Effectors this robot serves as the transfer of goods based on the color of semiautomatic. Overall, this automation system consists of a robot arm, conveyor static form of the incline as a place of objects, and containers by color. This system consists of a color sensor, ATMEGA32 microcontroller, and 6 (six) pieces as actuator servo arm. Color sensor consisting of photodiode as the receiver reflected light intensity of LEDs Red-Green-Blue (RGB) are emitted into the object. These sensors serve as inputs the detected object color, the color sensor readings are then processed through a microcontroller and calculation of the number of objects based on color which is then displayed on the LCD 16x2. For positioning the target object to the laying of container based on the color mapping method is used arena. This position can be set manually, and then stored in the memory of the microcontroller as a reference for actions or movements of the robot arm.[9] The problem we are attempting to sole is to create an autonomous robot that can be navigate with in an area, identify objects based on customer specified criteria, and then sort by relocating them to a specific location. The customer can specify the sorting criteria prior to operation. Identify desired object location using sensor. Obtain status information through sensor. Capture object, identify color and put according to color.

Most of the color sensors contain a white light LED emitter and three separate receiver. The light is reflected off of the target such as a blue piece of paper and returns to the sensor , The
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receivers are tuned to look for a specific wavelength of light working out its RGB or Red, Green, and blue values. Compared to human classification which is tedious and error prone[1], our robot will provide consistent and accurate color recognition. The main goal for this research is to perform successful classification under different color saturation, variations of environment lighting and light reflections. 1.1 Purpose: The purpose of this project is to create an autonomous robot that can navigate within an area, identify objects and based on customer specified criteria, and then sort by relocating them to a specific location. The customer can specify the sorting criteria prior to operation. Typically color sensors have been used to enable a machine to sense the presence of a target, such as determining if a part was painted or not. So purpose of our project is to identify the object color using sensor. So by using this we can identify the color of any fruit, pencil color or any object and according to arrange the object. Color sensors can also be used for sorting by color. This can be evident on assembly lines where packaging pencils may be sorted according to their color. The color sensors are able to recognize the color of the pencil and effectively sort them into the correct categories. They are also used in medical laboratory equipment. Some sensors can recognize different colors or distinguish between shades of a color, in a cosmetic or textile process, for instance. Other color sensors dont actually detect color but rather the contrast of a color mark against a background.

Fig.1.1 Color analysis By using this system we can also successfully performed handling station task, namely pick and place mechanism with the help of vision application. The non specific color gave 80% accuracy, while testing with specified color resulted in 100% accuracy. Under the ideal condition the system detect the object with 100% success rate.[2]

1.2 Scope of the Project The scopes of this project are: 1. Design a system that can identify RGB color from an object 2. Fabricate the system using: Color sensor DC motor Relay Microcontroller Conveyor structure Create a program that can use to identify RGB color. Run the programming system.

2. LITERATURE SURVEY
2.1 Intended Audience and Reading Suggestions Shaun, (2007) describes the outline of the development of the color sensor meant for the radiation-robot used for the alignment of sample for various experiments in a radiation environment near nuclear beam line of 3MV Tandem pellet on Accelerator at Institute of Physics, Bhubaneswar. In this paper a comparative study between the APD (Advanced Portable Detector) and LDR for their sensitivity towards different colors also discussed. A cost effective as well as with reasonable accuracy and precision, a color sensor is developed with a array of LDRs, where the biasing voltage is very less compared to APD based color sensor. This sensor is used in a micro-controller based robotic arm and successfully able to distinguish up to 8 colors. This can be enhanced to 256 colors. This work is the first developmental stage of the robot, which will be used for alignment of the sample sensing laser of different color in high-dose radiation environment. Khojastehnazhand,(2010) Grading systems give many kinds of information such assize, color, shape, defect, and internal quality. Among these color and size are the most important features for accurate classification and/or sorting of citrus such as oranges, lemons and tangerines. Basically, two inspection stages of the system can be identified: external fruit inspection and internal fruit inspection. The former task is accomplished through processing of color images, while internal inspection requires special sensors for moisture, sugar and acid contents. In this paper, an efficient algorithm for grading lemon fruits is developed and implemented in visual basic environment. The system consists of two CCD cameras, two capture cards, an appropriate lighting system, a personal computer and other mechanical parts. The algorithm initially extracts the fruit from the background. The samples of different grades of lemon are situated in front of the cameras and are calibrated off-line. Then information on the HSI color values and estimated volumes of fruits are extracted and saved in a database. By comparing the information during sorting phase with the available information inside the database, the final grade of the passing fruits is determined. This algorithm can be easily adapted for grading and/or inspection of other agricultural products such as cucumber and eggplant. Hymen Goddard of Logan Company patented the first roller conveyor object sorting system in 1908. Its initial application was not very popular, and it wasnt until it was introduced in the automotive industry that it was able to prosper. In 1919, the first powered and free conveyors object sorting system were introduced into the mass production of automobiles. The conveyor quickly became a popular means of transporting heavy materials within manufacturing facilities. The application of the conveyor branched out to coal mining in the 1920s, where the technology underwent considerable changes. In this object sorting system Conveyor belts were designed made of layer of cotton and rubber coverings. During the manufacturing increase of World War 2, manufacturers created synthetic materials to make belting because of the scarcity of natural components. Todays conveyor belting is made from an almost endless list of synthetic polymers and fabric and can be tailored to any requirements. Possible uses of conveyors have broadened considerably since the early days and they are used in almost any industry where a material have to be handled, stored or dispends.

Some researches, like Shahin and Symmons, foung that it is appropriate for the task of color recognition because they have good performance, they are easy to retain, easy to change classification criteria, simple to setup, and execute.[1]

3. OVERALL DISCRIPTION
3.1 Product Feature 3.1.1 LCD display feature: 5 x 8 dots with cursor Built-in controller (KS 0066 or Equivalent) + 5V power supply (Also available for + 3V) 1/16 duty cycle B/L to be driven by pin 1, pin 2 or pin 15, pin 16 or A.K (LED) N.V. optional for + 3V power supply

Table.3.1.1 Pin description

3.1.2 Features of color sensor High-Resolution Conversion of Light Intensity to Frequency Programmable Color and Full-Scale Output Frequency Communicates Directly With a Microcontroller Single-Supply Operation (2.7 V to 5.5 V) Power Down Feature Compliant Surface-Mount Package

3.1.2 Functional block diagram of color sensor The TCS230 programmable color light-to-frequency converter combines configurable silicon photodiodes and a current-to-frequency converter on a single monolithic CMOS integrated circuit. The output is a square wave (50% duty cycle) with frequency directly proportional to light intensity (irradiance). 3.1.3 AVR features High-performance, Low-power Atmel AVR (Advanced Virtual RISC) 8-bit Microcontroller Advanced RISC Architecture 131 Powerful Instructions Most Single-clock Cycle Execution 32 8 General Purpose Working Registers Fully Static Operation On-chip 2-cycle Multiplier 32Kbytes of In-System Self-programmable Flash program memory 1024Bytes EEPROM 2Kbytes Internal SRAM In-System Programming by On-chip Boot Program Programming Lock for Software Security Real Time Counter with Separate Oscillator Four PWM Channels Programmable Serial USART
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 Master/Slave SPI Serial Interface Programmable Watchdog Timer with Separate On-chip Oscillator On-chip Analog Comparator Special Microcontroller Features Internal Calibrated RC Oscillator I/O and Packages 32 Programmable I/O Lines 3.2 User documentation ATMega32 The ATmega32 provides the following features: 32Kbytes of In-System Programmable Flash Program memory with Read-While-Write capabilities, 1024bytes EEPROM, 2Kbyte SRAM, 32 general purpose I/O lines, 32 general purpose working registers, a JTAG(Joint Test Action Group) interface for Boundary scan, On-chip Debugging support and programming, three flexible Timer/Counters with compare modes, Internal and External Interrupts, a serial programmable USART, a byte oriented Two-wire Serial Interface, an 8-channel, 10-bit ADC with optional differential input stage with programmable gain, a programmable Watchdog Timer with Internal Oscillator, an SPI serial port, and six software selectable power saving modes. The Idle mode stops the CPU while allowing the USART(Universal Synchronous Asynchronous Receiver Transmitter), Two-wire interface, A/D Converter, SRAM, Timer/Counters, SPI port, and interrupt system to continue functioning. The Power-down mode saves the register contents but freezes the Oscillator, disabling all other chip functions until the next External Interrupt or Hardware Reset. In Power-save mode, the Asynchronous Timer continues to run, allowing the user to maintain a timer base while the rest of the device is sleeping. The ADC Noise Reduction mode stops the CPU and all I/O modules except Asynchronous Timer and ADC, to minimize switching noise during ADC conversions. In Standby mode, the crystal/resonator Oscillator is running while the rest of the device is sleeping. This allows very fast start-up combined with low-power consumption. In Extended Standby mode, both the main Oscillator and the Asynchronous Timer continue to run.[6] 3.3 Design and implementation constraint 3.3.1 Sensing circuit This circuit can be used to sense and differentiate between different colors. This circuit demonstrates the principle and operation of a simple color sensor using LDR. The circuits is divided into three parts: Detector. Comparator Output When the light of a particular color object fall on LDR its resistance decreases and an output voltage is produced. This voltage is dependent on the intensity and wavelength of different color. For it is needed to set reference voltage of comparator according to the requirement.
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For example, if set reference voltage at positive pin with 0.38 volts, the LDR becomes sensitive to blue light. When blue light falls on the LDR, and output of approximate voltage 0.28 produced, this glows the output LED.

Fig.3.3.1 Sensing circuit But if a yellow color light on LDR the input voltage at the comparator is around 0.7 volts at the negative pin of comparator and the output LED doesnt glow. There are three LEDs of Red, Green and Blue are arranged along with special LDRs, which will just allow either Red, Green or Blue lights to pass through. The working principle of LDR is that when a light falls on LDR its resistance reduces and it allows the current to pass through it. When the light from the LED falls on any of the three color object, it will reflect back on the LDR. These LDR will only allow any one color to pass through it and this is how it will sense the color of object. There are LEDs placed in order to let the user know that which colored object has been sensed by the sensing circuit. The signal from the sensing circuits is sent to the controller circuit consisting of power circuit, rectifier circuits and microcontroller. 3.3.2 Transformer By appropriate selection of the ratio of turns, a transformer thus allows an alternating current (AC) voltages to be stepped up by making N, greater than Np, or stepped down by making N, less than Np. Here the 230 volts power supply from the mains if transformed by a 120-12 step down center tap transformer. This AC voltage is needed to be converted to DC for supplying it to controller and DC motor. A transformer is a static device that transfers electrical energy from one circuit to another through inductively coupled conductors, the transformer couples. A varying current in the first or primary winding creates a varying magnetic flux in the transformers core and thus a varying magnetic field through the secondary winding. This varying magnetic field induces a varying electromotive force or voltage in the secondary winding. This effect is called mutual inductance. If a load is connected to the secondary. And electric current will flow in the secondary winding and electrical energy will be transferred from the primary circuit through the transformer to the load. In a ideal transformer, the induced voltage in the secondary winding(Vs) is in proportion to the primary voltage(Vp), and is given by the ratio of the number of turns in the secondary (Ns)to the number of turns in the primary(Np)[7]
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Vs Ns ___ = ____ Vp Np 3.3.3 Rectifier circuits The signals from the micro-controller are then given to the robotic arm through the switching circuit. These signals will control the arm and gripper movement and will place the object picked from conveyor belt to three different places in order to segregate them. The switching circuit gives the option of manual operation of arm movement as well as gripper operation. The automation switch on the board will operate the system automatically.

Fig. 3.3.3 Full wave rectifier A rectifier is an electrical device that converts alternating current (AC), which periodically reverses direction, to direct current (DC), which is in only one direction, a process known as rectification. A full-wave rectifier is used, which converts the whole of the input waveform to one of constant polarity (positive or negative) at its output. Full-wave rectification converts both polarities of the input waveform to DC (direct current),a n d i s m o r e e f f i c i e n t . 6 A d i o d e s a r e u s e d f o r v o l t a g e r e c t i f i c a t i o n . T h e r e f o r e t h e A C voltage is now converted pulsating DC. While half-wave and full-wave rectification suffice to deliver a form of DC output, neither produces constantvoltage DC. In order to produce steady DC from a rectified AC supply, a smoothing circuit or filter is required. This pulsation is removed by 1000 micro-farad capacitor filter circuit. Sizing of the capacitor represents a tradeoff. For a given load, a larger capacitor will reduce ripple but will cost more and will create higher peak currents in the transformer secondary and in the supply feeding it. In extreme cases where many rectifiers are loaded onto a power distribution circuit, it may prove difficult for the power distribution authority to maintain a correctly shaped sinusoidal voltage curve. The output of the filter circuit is pure DC which is then supplied to controller motors and sensors.

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3.3.4 DC motors: Motor detail Gripper : 9V,60 rpm Turn table:24V,30 rpm Up /down: 12V , 30 rpm

The DC motor is used to control the arm and turn table movement are connected to controller circuit and receives signal from microcontroller. There are IR sensors installed in order to accurately identify ground and drop place. 3.3.5 Robotic ARM and Gripper Gripper: 9V,60rpm DC motor is used to control the gripper movement, for opening and closing of the gripper. The DC motor receives its signal form the controller for performing gripping and dropping operations. The gripper has been specially designed in order to grip rectangular or square objects from the running conveyor and dropping them at programmed locations. An industrial robot is defined as automatically controlled, reprogrammable, multipurpose manipulator programmable required axes. The parameters such as degrees of freedom, work volume, payload, accuracy, repeatability, acceleration and robot kinematics are considered before designing the robotic arm. The robotic arm movements are controlled by the DC motor of 25 rpm. Its motion is restricted b y placing the IR sensor and programming the controller accordingly to limit the robotic arms movement.[8] 3.3.6 Conveyor belt Here the conveyor motor receives power and signal from the central supply through rectifier and control circuits. The control circuit consisting of a an potentiometer will allow the user to manually control the speed of conveyor belt by the regulatory know. Polyester is used as belt material. The conveyor belt consists of two or more pulleys, with a continuous loop of material the conveyor belt- that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler. There are two main industrial classed o the belt conveyors: those in general material handling such as those moving boxes along inside a factory and bulk material handling such those used to transport industrial and agricultural materials, such as gain , coal etc. generally in outdoor locatio n s .

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Belt conveyors provide a smooth solution for situations where one need a change in elevation for example inter floor situations or to receive or deliver products to a mezzanine level Metering precise positioning Scanning in conjunction with code readers Tracking where precise positional control is required for sorting Induction precise feeding into other conveyors at junction.

` Fig3.3.6 Conveyor belt.

3.3.7 Power supply design Power supply is the first and the most important part of our project. For our project we require +5V regulated power supply with maximum current rating 500mA. Following basic building blocks are required to generate regulated power supply.[7]

Fig.3.3.7 Block diagram of power supply

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Step down transformer

Step down transformer is the first part of regulated power supply. To step down the mains 230V A.C. we require step down transformer. Following are the main characteristic of electronic transformer. 1) Power transformers are usually designed to operate from source of low impedance at a single freq. 2) It is required to construct with sufficient insulation of necessary dielectric strength. 3) Transformer ratings are expressed in voltamp. The volt-amp of each secondary winding or windings is added for the total secondary VA. To this are added the load losses. 4) Temperature rise of a transformer is decided on two well-known factors i.e. losses on transformer and heat dissipating or cooling facility provided unit.

Rectifier design

R.M.S. Secondary voltage at secondary of transformer is 12V. So maximum voltage Vm across Secondary is = Rms. Voltage x 2= 12 x 2= 16.97V D.C. O/p Voltage at rectifier O/p is Vdc = 2Vm/ PIV rating of each diode is PIV = 2 Vm. & maximum forward current which flow from each diode is 500mA. So from above parameter we select diode IN 4007 from diode selection manual. Filter design

Generally a rectifier is required to produce pure D.C. supply for using at various places in the electronic circuit. However, the o/p of rectifier has pulsating character i.e. if such a D.C. is applied to electronic circuit it will produce a hum i.e. it will contain A.C. and D.C. components. The A.C. components are undesirable and must be kept away from the load. To do so a filter circuit is used which removes (or filters out) the A.C. components reaching the load. Obviously a filter circuit is installed between rectifier and voltage regulator. In our project we use capacitor filter because of its low cost, small size and little weight and good characteristic. Capacitors are connected in parallel to the rectifier o/p because it passes A.C. but does not pass D.C. at all.

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Design of Filter Capacitor formula for calculating filter capacitor is, C = 1 ---------------------43 r f RL.

r f RL

= ripple present at o/p of rectifier. (This is maximum 0.1 for full wave rectifier.) = frequency of mains A.C. = I/p impedance of voltage regulator IC.

And voltage rating of filter capacitor is double of Vdc i.e. rectifier o/p which is 20V. So we choose 1000 f / 25V filter capacitor.[7]

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4. SYSTEM FEATURES AND DESIGN

4.1 System architecture

Color Sensor

AVR
Sensor Conditioning circuit

Microcontroller

Display

Power Supply
Fig.4.1 Block diagram of the system

Unit
Fig.4.1 Block diagram of object sorting system This system consists of a color sensor, ATMEGA32 microcontroller, The design of the robot arm consists of 4 (four) degrees of freedom with a gripper (clamp) as Effectors this robot serves as the transfer of goods based on the color of semi-automatic. Overall, this automation system consists of a robot arm, conveyor static form of the incline as a place of objects, and containers by color (red, blue, green, and black). Color sensor consisting of photodiode as the receiver reflected light intensity of LEDs Red-Green-Blue (RGB) are emitted into the object. These sensors serve as inputs the detected object color, the color sensor readings are then processed through a microcontroller and calculation of the number of objects based on color which is then displayed on the LCD 16x2. For positioning the target object to the laying of container based on the color mapping method is used arena. This position can be set manually, and then stored in the memory of the microcontroller as a reference for actions or movements of the robot arm.[5]

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4.1.1 AVR microcontroller Architecture

Fig.4.1.1(a) Architecture of ATMega32 controller

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The atmel AVR ATMega32[5][6] is low power CMOS 8 bit microcontroller based on the AVR enhance RISC architecture.The AVRcore combines a rich instruction set with 32 general purpose working registers. All the 32 registers are directly connected to the Arithmatic logical uint allowing two independent registers to be accessed in one single instruction executed in one clock cycle. The resulting architecture is more code eficient while achieving throughputs up t the ten times faste then the conventional CISC microcontrollers.[6] Pin out

Fig.4.1.1(b) Pin diagram of AVR microcontroller VCC :Digital supply voltage. GND: Ground. Port A (PA7..PA0): Port A serves as the analog inputs to the A/D Converter. Port A also serves as an 8-bit bi-directional I/O port, if the A/D Converter is not used. Port pins can provide internal pull-up resistors (selected for each bit). The Port A output buffers have symmetrical drive characteristics with both high sink and source capability. When pins PA0 to PA7 are used as inputs and are externally pulled low, they will source current if the internal pull-

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up resistors are activated. The Port A pins are tri-stated when a reset condition becomes active, even if the clock is not running. Port B (PB7..PB0): Port B is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for each bit). The Port B output buffers have symmetrical drive characteristics with both high sink and source capability. As inputs, Port B pins that are externally pulled low will source current if the pull-up resistors are activated. The Port B pins are tri-stated when a reset condition becomes active, even if the clock is not running. Port B also serves the functions of various special features of the ATmega32 . Port C (PC7..PC0) : Port C is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for each bit). The Port C output buffers have symmetrical drive characteristics with both high sink and source capability. As inputs, Port C pins that are externally pulled low will source current if the pull-up resistors are activated. The Port C pins are tri-stated when a reset condition becomes active, even if the clock is not running. If the JTAG interface is enabled, the pull-up resistors on pins PC5(TDI), PC3(TMS) and PC2(TCK) will be activated even if a reset occurs. The TD0 pin is tri-stated unless TAP states that shift out data are entered. Port C also serves the functions of the JTAG interface and other special features of the ATmega32 Port D (PD7..PD0): Port D is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for each bit). The Port D output buffers have symmetrical drive characteristics with both high sink and source capability. As inputs, Port D pins that are externally pulled low will source current if the pull-up resistors are activated. The Port D pins are tri-stated when a reset condition becomes active, even if the clock is not running. Port D also serves the functions of various special features of the ATmega32 RESET: Reset Input. A low level on this pin for longer than the minimum pulse length will generate a reset, even if the clock is not running. XTAL1: Input to the inverting Oscillator amplifier and input to the internal clock operating circuit. XTAL2 :Output from the inverting Oscillator amplifier. AVCC: A VCC is the supply voltage pin for Port A and the A/D Converter. It should be externally connected to VCC, even if the ADC is not used. If the ADC is used, it should be connected to VCC through a low-pass filter. AREF: AREF is the analog reference pin for the A/D Converter.

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4.2 Data flow diagram

Fig.4.2 Data flow diagram

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5. EXTERNAL INTERFACE REQUIREMENT

5.1 Hardware interface

Fig.5.1(a) System hardware interface The crystal are connected between the XTAL1 and XTAL2 pin. The LCE which we want to show the output that which color are sensed by the sensor. The device driver circuit are connected with 4 pin of controller. We are using motor driver circuit which are used to rotate the arm and for positioning of the robot. The color sensor is connected with the pin 14 of microcontroller which is RXD. The IR object sensor circuit is connected with the 7th pin of port
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D. The color object sensed by the sensor is transmit the signal to the microcontroller and then it proceeded the arm of robot. In this way the all assembly get works.[5] Sensor conditioning system

The color sensing circuit of the project contains three different color LED emitter and separate receivers. The light is reflected off of the target such as a blue piece of paper and returns to the sensor. The receivers are tuned to look for specific wavelength of light working out its RGB or Red, Green and Blue values. The light sensors are able to record the components of the reflected light and its intensity. The sensor then compares these values to the settings on the computers and determines the necessary actions. Many of the color sensors today have the ability to recognize the Red, Blue Green color.

Fig 5.1(b) RGB color sensor circuit When a primary colored light ray falls on the system, the glass plate corresponding to that primary color will allow that specific light to pass through. But the other two glass plates will not allow any light to pass through. Thus only one LDR will get triggered and the gate output corresponding to that LDR will become logic 1 to indicate which color it is. Similarly, when a secondary colored light ray falls on the system, the two primary glass plates corresponding to the mixed color will allow that light to pass through while the remaining one will not allow any light ray to pass through it. As a result two of the LDRs get triggered and the gate output corresponding to these will become logic 1 and indicate which color it is.

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LDR or light dependent resistors are very useful especially in light/dark sensor circuits. Normally the resistors of an LDR is very high, sometimes as high as 1000000 ohms, but when they are illuminated with light resistance drops dramatically. When a light level of 1000 lux(bright light) is directed towards it, the resistance is 400R(ohms).When a light level of 10 lux(very low light level)is directed towards it, the resistance has risen dramatically to 10.43 (10430000 ohms).

Fig.5.1(c) Sensing circuit When the light level is low the resistance of the LDR is high. This prevents current from flowing to the base of the transistors. Consequently the LED does not light. Figure shows LED based LDR Sensor However, when light shines onto the LDR its resistance falls and current flows into the base of the first transistor and then the second transistor. The LED lights. The preset resistor can be turned up or down to increase or decrease resistance, in this way it can make the circuit more or less sensitive. The LEDs are water clear when turned off. Black electrical tape surrounds the photocell in the center of the LEDs. The tape blocks the direct light from the LEDs from reaching the photocell, thus detecting only reflected light. A f t e r t h e a m o u n t o f r e d l i g h t , g r e e n l i g h t , a n d b l u e l i g h t i s m e a s u r e d , e a c h component is individually scaled based on minimum and maximum values obtained at calibration. One-time calibration consists of aiming the completed sensor first at a white piece of paper and then at a piece of black conductive foam. The maximum and minimum values are plugged into the EEPROM of the microcontroller. Scaling based on actual data allows the individual attributes of that particular sensor and set of LEDs to be accounted for.

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Alternatively, one can adjust the balance of the colors in hardware by using with three separate trimpots (trimmer potentiometers). Dialing a trimpo t c h a n g e s t h e brightness of a particular LED. For example, if there is too much red light being sensed, simply increase the resistance to decrease the LED brightness by turning the trim pot attached to the red LED. Include a minimum fix ed resistor value (100 ohms to 150 ohms) in s e r i e s w i t h e a c h trim pot so that if one accidentally dial the trim pot to 0 ohms the LED won't be damaged. T h e o b j e c t w h o s e c o l o r i s r e q u i r e d t o b e d e t e c t e d s h o u l d b e p l a c e d i n f r o n t o f t h e system. The light rays reflected from the object will fall on the three convex lenses which are fixed in front of the three LDRs. The convex lenses are used to converge light rays. This helps to increase the sensitivity of LDRs. Blue, green and red glass plates (filters)are fixed in front of LDR1, LDR2 and LDR3 respectively. When reflected light rays from the object fall on the gadget, the color filter glass plates determine which of the LDRs would get triggered When all the LDRs get triggered or remain untriggered, one will observe white and black light indications respectively. Following points may be carefully noted: 1.Potmeter VR1,VR2 and VR3 are used to adjust the sensitivity of the LDRs. 2. Common ends of the LDRs should be connected to positive supply. 3. Use good quality light filters. The LDR is mounted in a tube, behind a lens and aimed at the object. The color glass filter should be fixed in front of the LDR as shown in fig. Make three of that kind and fix them in a suitable case. IR sensing circuit

It is the same principle in all Infra Red proximity sensors. The basic idea is to send infra red light through IR-LEDs, which is then reflected by any object in front of the sensor. Then all one have to do is pick-up reelected IR light. For detecting the reflected Ir light that was emitted from another LED of the exact same type. Thus is an electrical property of Light Emitting Diode(LED) which is the fact that led produce a voltage difference across its leads when it is subjected to light. As if it was a photo cell, but with much lower output current. In other words, the voltage generated by the leds cant be in any way used to generate electrical power barely be can detected.

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Fig.5.1(d) IR sensing process 5.2 Software interface The software responsible for functioning of the hardware part is written in embedded c language and compile using keil compiler.

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7. OTHER REQUIREMENT
7.1 Application Historically, components used for color sensing were considered expensive and required precision support circuitry, limiting their application mostly to specialized instrumentation. However, new technologies of color sensors with higher levels of integration are becoming available, allowing for more cost-effective solutions. As the cost of color sensing comes down, the number of applications using color sensing is increasing. Solomon (2004) explain several example applications using color sensor. The following are five examples of unique situations requiring innovative solution. 1. Sorting automotive parts with different colors. A manufacturer of automotive parts needs to differentiate parts whose only visible difference is a slight variation in color. One part is black, the other a dark grey. Because efficiency demands that the part be sorted at a high rate of speed, the opportunity for mistakes is extremely high. By using advance color sensing technology, the manufacturer can sort these parts at an enhanced rate of speed, saving time and virtually eliminating errors. 2. Assembly of medical colures with different color components In this situation, containers of liquid medications consist of an aluminum cap with a plastic cover. A complete closure assembly requires the assurance of proper color combination of two components. Because of this absolute necessity of color accuracy, color sensing technology proves invaluable. 3. Lumber sorting by color. Color cording has become a standard method of differentiation in the lumber industry. Not only different types of lumber but the grade, quality and intended purpose of the lumber is indicated by color. Because the environments in which lumber is sorted can be highly abusive, it is recommended that protective covers be employed to protect the fiber optics used for this process. 4. Color sensing in the food industry. Sensing a white target on a white background is challenging using conventional photoelectric sensors. A manufacturer who needs to insure the presence of the white cap on a jar of mayonnaise improves accuracy with a color sensor that employs the RGB color concept. This technology improves the contrast between two slightly different whites.
5. Ammunition final inspection and sorting process.

An ammunition manufacturer codes the style and caliber of bullets with various colors on the tips. The need to insure that the proper type and caliber of product are correctly packaged necessitates the automation of the product line with color sensing technology. Because of the critical nature of this application, it is recommended that two color sensing stations be implemented to add an extra safety margin to the operation.
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Industrial applications require some sort of automated visual processing and the classification of items placed on a moving conveyor. A typical process comprises of: (i) Looking at the items on the conveyor via some type of sensor such as a camera. (ii) Localizing any single item. (iii) Classifying the item based on a set of features such as shape. (iv) Performing the necessary action depending on the classifications made. Bozeman and Yal-cin (2002) in their journal explains about a Visual classification setup in an industrial setting typical setup is as shown in Fig. 2.5. In this journal state that how items at random positioned and oriented to be moving on a conveyor. A camera located above the conveyor views the items orthographically. They assume that there is an item separator placed before the camera so that the incoming items are not overlapping which is a realistic assumption in many manufacturing environments. A sensing device signals the presence of perception that is instead of processing the whole image, only areas that are deemed interesting and thus Calling for attention are analyzed.

Fig 7.1 Industrial application 7.2 Advantages 1. Human errors can be avoided with the help of automated sorting system. 2. By using this system we- c-an also successfully performed handling station task, namely pick and place mechanism . 3. The non specific color gave 80% accuracy, while testing with specified color resulted in 100% accuracy. 4. Under the ideal condition the system detect the object with 100% success rate.

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7.3. Disadvantages 1. The major problem of automated sorting and grading is one of socio-economic effects, which tend to reduce employment when the number of operators required in the processing line is reduced. 2. It is not suitable in processes where manual skill is necessary or economically more attractive. It requires higher initial and maintenance cost and there may be the need for a precise understanding of the process for programming to achieve the required product quality Equipment associated problem involves radiance on accurate sensors to precisely measure process condition and the increased risk, delays and cost if the automatic system fails. 7.4 Future Scope This project involves the sorting of objects through color sensor the future advancements can be done by increasing the efficiency of the color sensor. The sensor is key component of project which aides in distinguishing the objects. Failing of which may result in wrong material handling. Thus it becomes vital that the sensor had a very high sense of sensitivity and ability to distinguish between colors. Another area of improvement is design of efficient gripper of Digital Image Processing (DIP) is a multidisciplinary science. The applications of image processing include: astronomy, ultrasonic imaging, remote sensing, medicine, space exploration,surveillance, automated industry inspection and many more areas. Different types of an image can be discriminated using some image classification algorithms using spectral features, the brightness and "color information contained in each pixel. TheClassification procedures can be "supervised" or "unsupervised". Wi th supervisedclassification, identified examples of the Information classes (i.e., land cover type) of interest in the image. These are called "training sites. The image processing software system is then used to develop a statistical characterization of the reflectance for each information class. Genetic algorithm has the merits of plentiful coding, and decoding, conveying complex knowledge flexibly. An advantage of the Genetic Algorithm is that it works well during global optimization especially with poorly behaved objective functions such as those that are discontinuous or with many local minima. MATLAB genetic algorithm toolbox is easy to use, does not need to write long codes, the run time is very fast and the results can be visual. The aim of this work was to realize the image classification using Matlab software. Matlab is a widely used software environment for research and teaching applications on robotics and automation, mainly because it is a powerful linear algebra tool, with a very good collection of toolboxes that extend Matlab basic functionality, and because it is an interactive open environment. The paper presents a toolbox that enables access to real robotic and automation (R&A) equipment from the Matlab shell. If used in conjunction with a robotics toolbox it will extend significantly their application, i.e. besides robotic simulation and data analysis the user can interact online with theequipment. Personal experience with this tool shows its usefulness for research applications, but also for teaching projects. With students, using Matlab means taking advantage of the reduced training required to start using it , if compare with other programming environments and languages that can also be used (Microsoft Visual C++or Visual Basic).
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An innovative approach for quality sorting of objects such as apples sorting in an agricultural factory, using an image processing algorithm. The objective of the approachare; firstly to sort the objects by their colours precisely; secondly to detect any irregularly of the colors surrounding the apples efficiently. An experiment has been conducted and the results have been obtained and compared with that has been performed by human sorting process and by color sensor sorting devices. Existing sorting method uses a set of inductive, capacitive and optical sensors do differentiate object color. Advanced mechatronics color sorting system solution with the application of image processing. Supported by Open CV, image processing procedure senses the circular objects in an image captured in real time by webcam and then extracts color and position information out of it. This information is passed as a sequence of sorting commands the manipulator that does pick and place mechanism. Extensive testing proves that this color based object sorting system works 100%accurate under ideal condition in term of adequate illumination, circular objects shape and color. The circular objects tested for sorting are silver, red and black. For non-ideal condition, such as unspecified color the accuracy reduces to 80%.

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CONCLUSION
The project works successfully and separates different colored objects using color sensor. The color sensor result was converted chiefly to the command that drive the handling system which drive the pick and place robot to pick up the object and place it into its designed place. There are two main step in color sensing part, objects detection and color recognitation. The system has successfully performed handling station task, namely pick and place mechanism with the help of color sensor. Thus a cost effective mechatronics system was designed using the simplest concept and efficient result was being observed. This system is a depicting the prototype of sorting systems which are used in industries.

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