Conveyor Belt Weighted Sorting System With Counter
Collaborated on an Arduino conveyor belt system that sorts payloads by weight, counts items in real time, and displays live readings on an LCD.
Technologies
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Introduction
I collaborated with a team of three to engineer a conveyor belt sorting system that separates payloads between two destinations based on weight. The system also counts payloads in real time, tracking items above and below a predefined threshold.
My main responsibility was programming the system and making the motors and sensors work together. This included Arduino programming in C++, servo motor implementation, ultrasonic sensor implementation, Force-Sensing Resistor (FSR) coding and testing, breadboard testing, simulations, and schematics.
The FSR sensor detects the payload weight and triggers the conveyor belt motor and servo mechanism when a package exceeds the set threshold. The system then directs packages to the correct destination and displays the current weight and item counts on an LCD.
Features and Functionality
- Efficient payload separation: Sorts payloads into two destinations based on their weight.
- Real-time payload counting: Tracks items above and below the predefined threshold.
- Advanced sensing: Uses Force-Sensing Resistor technology to detect payload weight.
- Arduino integration: Interfaces the FSR sensors, ultrasonic sensor, servo motors, conveyor motor, and LCD through an Arduino microcontroller.
- Motor coordination: Coordinates the conveyor belt motor and servo mechanisms for efficient sorting.
- User interface: Displays payload counts and current weight readings on an LCD.
How It Works
The Arduino coordinates the ultrasonic sensor, FSR sensor, servo motors, conveyor belt motor, and LCD so the components can work together in sequence.
Control Simulations
These simulations show how the Arduino connects to the LCD, FSR sensor, and ultrasonic sensor so the system can read inputs and update the display in real time.
Ultrasonic Sensor to Servo Motor
When the ultrasonic sensor detects an item within the set distance, it signals the first servo motor to extend and push the payload onto the running conveyor belt.
Servo to LCD Counter
Every time the first servo motor is activated, the LCD updates with the total number of scanned items so the user can track throughput while the system runs.
FSR Sensor to Sorting Servo
The FSR sensor measures the payload weight. If the payload is over the threshold, a second servo motor extends to guide it to the designated area. If it is under the threshold, the servo stays closed and the payload continues to the end of the belt.
Future Improvements
- Introduce machine learning algorithms to adjust sorting criteria based on historical data.
- Connect the system with inventory management software to streamline operations.
- Build a dashboard with real-time analytics for sorting performance, payload distribution, and system efficiency.
Conclusion
The conveyor belt sorting system demonstrated the practical application of engineering principles, sensor technology, and embedded programming. Working with a team to design and implement the system gave me hands-on experience with motor coordination, FSR weight detection, Arduino control logic, breadboard testing, and real-time data display.