Design and Implementation of an IR Sensor-Based Automated Counting and Sorting Conveyor Belt System for Industrial Automation

In modern industrial automation, the need for efficient material handling and quality control is critical. This research presents the design, development, and implementation of an automated conveyor belt system that utilizes Infrared (IR) sensors for object counting and sorting based on dimensional attributes. The system is integrated with both Arduino UNO and Programmable Logic Controllers (PLCs), which enhance its reliability and scalability in industrial environments.
The primary objective of this project is to reduce human intervention, minimize errors, and increase operational efficiency by automating the sorting process. The IR sensors detect the presence and size of objects as they pass along the conveyor, and signals are processed by the Arduino to actuate a sorting mech- anism. The PLC manages higher-level control tasks, ensuring seamless integration and coordination between components.
The system was tested under various conditions to evaluate its performance, including sorting accuracy, speed, and reliability. The results indicate that the IR sensor-based system achieved high accuracy in item counting and sorting with minimal delay, outperforming traditional manual methods. Furthermore, the au- tomation process led to improvements in production throughput, quality assurance, and labor cost reduction.
This research contributes to the advancement of automated material handling systems, offering a cost-effective and scalable solution for industries aiming to streamline their production lines while maintaining high-quality standards.

Industrial Automation, Conveyor Belt, IR Sen- sors, Automated Sorting

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