# PLC-Controlled Intelligent Conveyor System with AI-Enhanced Vision for Efficient Waste Sorting
## 2 System
### Components  
The system is composed of several fundamental components, including a camera, conveyor, actuator, PLC, and motor controller. Each of these elements plays an essential role in the effective execution of the object detection and sorting process. The camera chosen for this system implementation is an ONN 1440p desktop webcam, which is equipped with autofocus capabilities and a ring light. The selection of this camera was based on its superior resolution quality combined with its cost-effectiveness, making it an ideal choice to consistently obtain clear images of items as they move along the conveyor belt. The autofocus capability is crucial for the system's ability to manage changes in the dimensions of objects without the need for manual intervention. This feature is indispensable in maintaining a uniform level of detection precision in various scenarios. The camera is installed at a right angle to the conveyor belt, facilitating the acquisition of distinct images of the items as they temporarily halt for examination. These images are subsequently sent to a Personal Computer (PC) through a USB interface, where they undergo analysis by a part-detection algorithm to recognize the items.  
The conveyor system, illustrated in Figure 4, enables the transport of objects within the system and is driven by a brushless DC motor, also shown in Figure 4, which is controlled by a motor driver that receives signals from the PLC. The velocity and distance traversed by the objects on the conveyor are controlled by the duration for which the motor receivespower. This design facilitates exact regulation of the conveyor's motion, guaranteeing that the objects halt momentarily in front of the camera for image capture before proceeding along the conveyor belt. The conveyor system is designed to handle the weight and dimensions of recycled materials, ensuring smooth operation.  
The sorting mechanism employs a stepper motor as the actuator, which guides a separator to direct cans into one container and bottles into another. The precise motion control of the stepper motor ensures that objects are sorted correctly based on their identified types. This sorting process is synchronized with the data received from the image processing system, ensuring real-time adjustments and smooth operation without interruptions.  
The system's control architecture is centered around an Allen-Bradley PLC with input/output (I/O) modules and an Ethernet port, which is responsible not only for controlling the conveyor and actuator but also for receiving input from the PC. The PLC functions through ladder logic, enabling real-time control and system monitoring. Additionally, it supports remote operation via a Human-Machine Interface (HMI), simplifying the process of monitoring system performance and implementing necessary adjustments. The flexibility of the PLC allows for future expansions or modifications to the system without significant hardware changes.  
The 60-watt brushless motor driver, shown in Figure 5, simplifies the operation of the conveyor by directly processing input signals (0-5 V) from the PLC. This design eliminates the need for extra control signal conditioning, thereby reducing the complexity of the system and easing the wiring process. The motor controller provides improved scalability and adaptability, allowing the integration of additional components or modifications to system parameters while maintaining reliable performance and reducing energy usage.  
All of the previously mentioned components are vital in enhancing the system's efficiency, ensuring that it operates effectively and reliably. Together, they enable precise, real-time object identification and classification. Their combined efforts ensure that the system functions seamlessly and autonomously, enhancing the overall process for optimal efficiency and productivity.  
Figure 4: (**Left**) Conveyor system for object transport. (**Right**) Oriental Motor BLM460S-GFV2 for precise motion control.