Design of a new sorting colors system based on PLC, TIA portal, and factory I/O programs

In the recent industry field, automation has become the most important role in production processes to improve efficiency, increase production, and reduce workers. Sorting the products based on their color is a common task in the industries, but using manual sorting may take a longer time and human error may occur, especially if the production quantities are very large. To contribute to improving the quality and speed of production, we have proposed a new system to automatically separate products based on their color. This article presents a new system for identifying and separating industrial products based on their colors. The implemented system consists of three sensors used to detect the colors of the products, four chutes, and two conveyor belts designed to guide objects along the manufacturing path, and three push mechanisms to place objects in their designated places. The system includes an emergency interface, a reset interface, a stop interface, as well as communication using the PN (PROFINET Process Field Net) protocol, a programmable logic controller, and a 1511-1 central processing unit. This system has been precisely programmed and simulated using FACTORY I/O software and TIA PORTAL software to control and monitor the system effectively. The Supervisory Control and Data Acquisition system also includes a Human–Machine Interface user interface for maximum control. The performance of this system was tested by sorting 250 objects of different colors. These tests resulted in the successful separation of a total of 85 blue objects, 89 green objects, and 86 gray (metallic) objects within a time period of 20 min. This system shows wide applicability in various industries including diamond mining, recycling, and grain manufacturing sectors.