PROTOTYPE OF AN AUTOMATIC SELECTOR OF
MATERIALS AND COLORS
Solís Quisiyupanqui, Lindembert Hernán.
lindersolis@hotmail.com
Carpena Del Pozo, María Julia.
maju 1_3@hotmail.com
Advisor professor: José Antonio Velásquez Costa
jvelasquezc@mail.urp.edu.pe
Professional School of Industrial Engineering - Ricardo Palma University
Summary
The automatic material and color selector prototype is an
industrial automation project that seeks to reduce costs and
production times in the material selection and distribution
process. It uses a detection method through the optical and
inductive sensors, which when recognizing the type of material
and color of the pieces send a signal to the programmable logic
controller (PLC), to activate a pneumatic actuator and perform the
selection and distribution of the material , obtaining as a result a
speed of selection and classification of 491 materials per hour
and reduction of personnel from 4 operators to 1. Consequently,
we have an optimization in times and selection, as well as a
reduction in costs.
P key words: PLC (Controller Logical
programmable), Valves, Sensors, Conveyor belt,
Automation.
TO bstract
The automatic selector of materials and colors is an industrial
automation project that seeks to reduce costs and production time
in the process of selection and distribution of materials. Uses a
method of detection using optical and inductive sensors which
recognize the material and color of pieces and then send a signal
to the Programmable Logic Controller (PLC) to activate an
automatic actuator for doing the selection and distribution of
material obtaining more speed of selection and classification of 491
materials per hour and reduction of workers from 4 to 1.
Therefore we have an optimized of time and selection and
additionally a cost reduction.
Key words: PLC (Programmable logic controller), Valve, Sensors,
Conveyor Belt, Automation
1. Introduction
The industry has experienced considerable quantitative growth in
terms of brands and products, which has undoubtedly generated
an environment of competition, with sales as the main
comparison.
Likewise, due to the competitive environment, companies depend
on their constant foray into improvement,
saving of weather, sales and
positioning in the market and some, for this reason, do not
generate acceptable productivity ratios or use of resources
In this sense, companies have been forced to evaluate the
economic and social benefits of the improvements that could be
obtained by automating, obtaining as a result a high degree of
productivity, quality, agility in their production process and
increased profitability for the company, thus justifying the
expenses that it may incur to obtain said objective
The Automatic Material and Color Selector is an industrial
prototype that allows us to select and distribute the pieces by
type of material and color. By using two sensors (inductive and
optical) the color of the part and the type of material are selected.
When the part is metallic, both sensors will be activated, if the
part is red, only the optical sensor will be activated and if the part
is matte black, no sensor will be activated. These sensors are
connected to the PLC inputs. Its signals are discreet. The motor
and the solenoid valves are connected to the outputs of the PLC.
This model can be used in various industries helping to select
and distribute different parts by type of material and color. Being
able to improve the productivity of the company, reducing
production costs and improving its quality.
The prototype automatic selector of materials and colors allows
us to carry out operations that are difficult to control manually,
simplifying the work so that the process does not require constant
checks in the selection of parts by type of material and color.
2. Background 3. Justification

Within the industry, different teams have been created to help The prototype solves a selection problem by type of material and
with the selection and distribution of materials, such as: color automatically and can also be used for teaching
programming, installation of PLC`s and wiring of controllers with
electrical devices (solenoid valves, sensors, motors and
2.1 Selector of diameter: Choose
switches), it is also useful for teaching electropneumatic
thoroughly the product according to its diameter. It can also be
installations.
configured to remove dirt, stones and other undesirable
materials. See fig. 1
Benefits Industry: mining (detection of ferrite materials); brewing
industry (selection of cans and glass bottles) the prototype
generally selects the entire manufacturing industry that uses the
selection and distribution of parts within its processes and at an
academic level benefits both the teacher and the student for the
best application and learning of these electro-pneumatic
components.

Fig. 1 Diameter selector

2.2 Color ball sorter
The process consists of filling containers with balls of a certain
color as selected with a button by an operator. See fig. 2
The prototype has the advantage that it is completely removable
and its structural design allows adding more components or
removing some of them easily and simply. It has been observed
that other projects of the same type have parts that are
permanently welded, riveted or fastened, making it very difficult
and complicated to change or add any of their electrical and
electro-pneumatic components.

3.1. Benefits of the prototype at the Industrial Level:

• To be able to regulate the selection speed.

• It uses pneumatic, electrical and control technology.

• Time reduction.
Fig. 2 Diameter selector
• Costs reduction.
• Reduction of operators from 4 operators to 1 operator.
(Based on a line of 4 operators)
2.3 Cocoa sorter

The selection of cocoa is also done manually for the beginning • Automation of processes. Improved
and end of the process, it is not an automated process requiring a • productivity. He
large number of operators for the selection of cocoa. See Fig. 3. • operator no needs to of Many
knowledge for operate he system
automated.
The processes seen above have served as the basis for the
development of the automatic material and color selection 3.2. Benefits of the Prototype at a General Level
prototype.
• The prototype can be completely assembled or
disassembled.
• It does not contaminate the environment.
• The prototype can be used for educational purposes.

• It can be used to practice programming and installation

of PLC´ś.

Fig. 3 First, second and third selection 4. Objectives

4.1. Overall objective

Optimize the selection processes in the Peruvian national

industry through the automation of the processes.
4.2. Specific objectives 5.3 Programmable Logic Controller PLC

1. Implement a selection system by type of material and color It is a solid state control system that monitors the condition of the
with electrical-pneumatic components. equipment that is connected as inputs.

2. Implement the automation of the selection process by type of

material and color, to reduce production times and costs. Based on a program stored in memory, written by the user, it
controls the status of the equipment that is connected as outputs.

5. Theoretical foundations
5.4 Linear actuators
Industrial Automation (automation; from ancient Greek auto:
guided by oneself) is the use of computerized systems or Single acting cylinders: With an air inlet to produce a one-way
elements to control machinery and / or industrial processes working stroke. See fig. 4
replacing human operators.

The scope goes beyond the simple mechanization of processes

since it provides human operators with mechanisms to assist
them in the physical efforts of work, automation greatly reduces
the sensory and mental need of the human. Automation as an
engineering discipline is broader than a mere control system,
encompassing industrial instrumentation, including field sensors
and transmitters, monitoring and control systems, data collection
and transmission systems, and applications. real-time software to
monitor and control plant operations or industrial processes.

Fig. 4 Single Acting Cylinder

Double acting cylinder: With two air inlets to produce output

5.1 Inductive sensors
and reverse work strokes. See fig. 5
It consists of a device made up of:

A ferrite coil and core, oscillator, detector circuit (switching stage),

solid state output.

The oscillator creates a high frequency field of oscillation by the

electromagnetic effect produced by the coil in front of the sensor
centered with respect to the axis of the coil. Thus, the oscillator
draws a known current. The ferrite core concentrates and directs
the electromagnetic field at the front, becoming the active surface
of the sensor.

When a metallic object interacts with the high frequency field,

currents are induced on the active surface. This causes a
decrease in the lines of force in the oscillator circuit and
consequently, the amplitude of oscillation decreases. The
Fig. 5 Double Acting Cylinder
detector circuit recognizes a specific change in amplitude and
generates a signal, which switches (pilots) the solid state output
"ON" or "OFF". When the metal object is removed from the
The scope of the prototype goes beyond the simple automation of
senate area, the oscillator generates the field, allowing the sensor
the processes since it helps human operators in the optimization
to return to its normal state.
of the process, this automated system greatly reduces manual
selection errors. With the help of scheduling, plant operations or
industrial processes can be monitored and controlled in real time.
5.2 Optical sensor

It is based on the reflection and refraction of infrared rays between an

emitter (photodiodes or phototransitors) and a receiver, this signal The programming allows us to establish the times and conditions
when interrupted by an object causes the sensor to detect. that the production process must meet, allowing repeatability and
sequence which facilitates better quality, greater efficiency,
integration with
business systems, increased productivity and reduced work.

The Automatic Material and Color Selector consists of two main

parts.

• The Command Part: It is the PLC, in which the

programming is carried out with the help of the FST v4.10
program from Festo, where the logical sequence of the
process is established.
• The Operational Part: They are the elements that make
the machine move and perform the desired operation.
The elements that make up the operative part are the
actuators (24V motor, 03 monostable valves, 02
Fig. 7 Front View
single-acting cylinders, 01 double-acting cylinder, 01
compressor, 01 optical sensor and 01 inductive).

6. Methodology

6.1 Problem Analysis

Currently there are many industrial companies in Lima - Peru

which have a selection process for their products or materials,
which are carried out manually and require one or two operators
for each type of material or product to make the selection.
Operators must be very focused on their work since a distraction
means sending a material or product through the wrong route,
which causes a delay in the process, making it slower and using
more human resources, causing an increase in production costs

Fig. 8 3D Three-Dimensional View

6.2 CAD design

The prototype design was done with AutoCAD software. See fig
6, 7, 8 and 9

Fig. 9 Profile View

6.3 Programming

Fig. 6 Horizontal View The prototype was programmed with a programmable logic
controller, which is the brain of the process. The PLC performs
automatic control of all the phases of the process. PLC
programming was developed with the programming language
called Instruction List. To do this, each of the input and output
modules must be configured so that the PLC recognizes the
program that will be downloaded from a PC. This computer must
have the software installed
programming as well as a communication port for the link one Solenoid valve 3/2
between PC and PLC. In fig. 10 you can see part of the program one Motor 24 V
that allows you to control the prototype process. one PLC Festus

5 Control buttons NO pushbuttons

one Source of 24V DC
feeding
one Power button NO button
one Polines two"

one Conveyor belt 50cms

3 "T" 4mm and 6mm
3 Silencers 1/8 "- 4mm
one Valve plug 4mm
10 Hoses 4mm and 6mm
Aluminum base 90 x 65 cms
13 Various supports aluminum
two Sensors Optoelectronics,
inductive

6.6 Commissioning
Fig. 10 PLC programming
For the start-up of the project, the following schedule was taken into
account:

6.4 Project Development

For the development of this Prototype, a material dispenser has

been designed which is attached to a conveyor belt.

The second and third cylinders are located on the right side of the
conveyor belt at 30.5cm and 40.5 cm from the dispenser
respectively, its objective being to expand pneumatically
according to the signal sent by the sensors that are on the side of
the conveyor belt separating thus, the materials according to their
type and color. Fig. 11 Gantt Chart

As some material passes through the dispenser, it is detected by a

The project is divided into 5 phases which are detailed below:
switch, which activates the first double-acting pneumatic cylinder,
which is controlled by a 5/2 valve which expels the material
towards the conveyor belt where the optical and inductive sensor PHASE 1: Feeder
will detect the type of material as well as its color, sending a signal
This phase begins with the double-acting cylinder extended and
to the PLC and the latter a signal to the solenoid valves which will
cubes of different colors and materials are stacked on top of it.
control the extension of the second and third single-acting cylinder,
See Fig. 12
achieving the distribution of each element through the various
ramps, if not no signal, the piece will continue its career until the
end of the conveyor belt being distributed by the last ramp
resulting in the selection and distribution of each material
depending on the characteristics detected by the sensors.

6.5 Materials Used

UNIT COMPONENT CHARACTERISTIC

two Pneumatic cylinders Single acting

one Pneumatic cylinder Double acting

Fig. 12 PLC programming
two Solenoid valves 5/2
PHASE 2: Dispenser PHASE 5: Distribution

This phase begins when the double-acting cylinder retracts after
3 seconds of activation of the conveyor belt, at this moment the
part falls activating the switch, which activates an electrovalve
that controls the air outlet so that the cylinder of double effect
expelling the cube towards the conveyor belt. See fig. 13.
This phase begins when the cubes are distributed by extending
the cylinders 2 and 3, which will allow the piece to move on its
respective ramp. See fig. 16.

Fig. 16 Distribution

Below is the process flow diagram:

Lit
Fig. 13 Dispenser do of
belt
transport

PHASE 3: Transportation
There are
This phase consists of a conveyor belt, which is driven by a 24v pieces

DC motor which is connected to a 5v voltage reducer, the motor

power is 20W. See fig. 14.
Expels
do for
cylinder
one

Analysis
Inductiv
or

It is
metal?

Fig. 14 Transport
Analysis
Sensor
Optical

Cylinder
PHASE 4: Selection 2 se ext.
ramp 1

In this phase the inductive sensors (with a detection distance of

1mm) and optical (with a detection distance of 7 cm to less), Plastic
Red?
select the materials. The inductive selects them according to the
type of material, recognizing metals and the optician recognizes Falls by

all colors except black. See fig. fifteen. ramp 3

Cylinder
3 ext.
ramp 2

Alm
here

Fig. 15 Selection
C onclusions
one. Allows the total or partial elimination of human
intervention
two. Reduces direct labor costs by eliminating these from
the product selection process

3. Since the products are more competitive, profits

increase, that is, if we reduce costs, we can speed up
the packaging process, thus increasing sales. Increase
production quality since automatic machines are more
Four. precise

5. In the medium and long term, thanks to the consistency

and uniformity of production, more reliable delivery times
are guaranteed.
6. The automatic material and color selector allows us to
differentiate between metallic and non-metallic materials
and the black color from the rest of the colors.

7. The automated system of the prototype optimizes the

production process in terms of:
a) Labor.
b) Production and / or classification times.
Fig. 17 Project Members: Lindembert Solís Quisiyupanqui,
c) Elimination of reprocesses. María Julia Carpena Del Pozo.

d) Costs and productivity.

REFERENCES

[one]. Pneumatic and Electropneumatic Automation. Salvador

Millán 1995.

[two]. Cembranos, Florencio J., Sequential control systems,

2002, Paraninfo, Madrid, 183 p

[3]. Deppert, W. and Stoll, K., Applications of pneumatics, 2001,

Alfaomega, Mexico DF, 135 p

[4]. Deppert, W. and Stoll, K., Pneumatic devices,

2001, Alfaomega, Mexico DF, 188 p

[5]. Guillén Salvador, Antonio, Industrial applications of pneumatics,

1988, Marcombo, Barcelona, 160 p Fig. 18 Project exhibition at the Maquinegocios Fair
2010
[6]. FluidSim-P Software Manual v4.2

[7]. Electropneumatics Manual, FESTO, 2002

[8]. http://www.jvelasquezc.com/automatizacion.html