systems folio_Yianni Tsoumaris

Year 12 unit ¾ Systems engineering folio

Colour sorting machine

By Yianni Tsoumaris
VCE number: 19184835R

Contents (part 1)

Criteria 1

• Statement of intention
• Design brief

o Introduction
o Constraints
o Considerations
• IPO diagrams
• Evaluation criteria

Criteria 2

• Detailed research
o Main components
o Colour sensor
o Servo motor

• Design options
o Justifications

• Final design option
• Flow diagram/Modelling and simulation

Criteria 3

• Process list
• Tools list
• Components list
• Risk/hazard assessment
• Gantt chart
• Onguard certificates
• References

Contents (part 2)

• Production record
o Final product

• Test 1
o Aim

o Reasoning
o Hypothesis
o Safety
o Methodology
o Expected results
o Conclusion
• Evaluation criteria
o Project evaluation
o Self-evaluation
o Evaluation of engineering process

Criteria 1

Statement of intent

In the modern world people are always looking for a machine or a product that will help sort
different colours more efficiently. One way to overcome this issue is by creating a colour sorting
machine that will be made to be environmentally sustainable which will be very effective. People are
spending to much time sorting different items and it takes up way to much time sorting items by
hand, instead people could be doing something else productive but due to the lack of a machine to
sort the items this cannot be done. By sorting the different items by hand, it could cause some strain
on the hand which could lead to long term injuries. By creating a colour sorting machine, the stress
of gaining long term injuries will greatly decrease and more productive things would be done while
the machine is sorting.

Design brief
Intro

The plan for my year 12 systems engineering class is to create a colour sorting machine that will
detect a colour and place it in its dedicated area. The system of the project is going to be built so
that with the flip of a switch, a coloured item will go past a colour sensor and it will be passed along
into its dedicated spot.

Constraints

The system must compose of two main functions which will include moving the board to the right
colour area and the sensor to detect the colours. The project must have the right casing that will be
able to fit every component inside as well as leaving no space for them to move around too much.
The project will also need to have a reasonable size for the input storages and the output storages so
that the items do not overfill and fall out. This will be done so that there is very little waste being
created. The project will need numerous components and it must have them to allow for the
machine to function as it should. The Arduino nano board is the most important component as it
holds the codes to make the machine detect the different colours and move the items to the correct
space. The school has given a budget of $250 and the project will need to be cost efficient which is
why the overall cost of the project will be no more than $100-$150 for every component and to
make the casing. The colour sorting machine will have to made so that there are no hazards or any
dangers that could cause the user any harm.

Considerations

The colour sorting machine should have clean look while also having a fancy style of pattern that will
suit the office workplace which is where it will be placed. An extra board would also be ideal so that
the machine could sort the items faster to make it more efficient. The sizing of the product will also
apply to the machine having two boards because the project should be bigger to fit more boards. An
extra casing would be ideal for each component so that no damage occurs inside and so that if one
component gets damaged, no other component will.

IPO diagrams

An IPO diagram is an important diagram that shows how a system works by giving us the input,
process and output of each system and describing what goes on in each section.

Colour sensor

Input Process Output

Coloured item Electrical power The item gets
passes through from the power placed in the
source detects the allocated spot
sensor
colour

Input Servo motor Output
Arduino codes Process
An action is
The codes send performed
instructions to the

servo motor

Electricity Electricity flows The project starts
through product to functioning
every component

Evaluation criteria

Below are many criteria questions that will aid in assessing the final product and how well the
product functions. It will allow for a product evaluation and a self-evaluation.

Project evaluation

Does the product look aesthetically attractive and does it suit the environment it will be placed in?

Justification: It is important that the project attracts the audiences attention to gain some use out of
the product.

Test: Ask a variety of random people if the product is aesthetically attractive.

Have there been any problems with the components of the project?

Justification: The project will have to have every component working and functioning so that project
can process each part and so that they can run to the standards that were expected.

Test: The project will be turned on to see if all the components will work and make sure that the
project functions to its full potential.

During the production process, were there any changes that were made to the project?

Justification: Any changes that have been made during the production process must be recorded and
checked to see if it has been a big change.

Test: To see if there are any changes, look back and make sure that the product meets the
requirements of the design brief.

Does the product fulfill its original purpose?

Justification: The project will have to meet the requirements set out in the design brief and make
sure the project can function.

Test: Test the project and make sure that that it functions and make sure it is able to fulfill its
purpose.

Does the project have any safety hazards that should be addressed?

Justification: If there is a safety risk in the project, it would have to be analysed and checked to see if
it can be resolved.

Test: To see if there are any safety hazards test each component separately to check for any
potential hazards.

Self-evaluation

Was I able to prevent any accident while building the project? Where there any accidents?
Justification: It is important that when building the project, there should be no hazards or injuries
when using the workshop tools and machinery to ensure everyone safety.

Test: Create a list of any injuries that have occurred and evaluate on what should’ve done to make it
safer.

How well was I able to control any hazard or danger to avoid any injuries? Was I able to avoid any
distractions that could’ve caused injuries?

Justification: It is extremely important that I make a clear workplace in order to eliminate any risks or
hazards that could cause an injury.

Test: Ask the people in your class including the teacher to see if avoided these injuries.

Were you able to overcome any difficult stages of the project?

Justification: Facing a difficult part of the project could create stress, you will need to overcome
these difficult stages.

Test: look back over the work and identify what you found difficult and compare it to the other
sections.

Would you say that you have gained a reasonable amount of knowledge while building this project?

Justification: Throughout the project, knowledge is important as it specifies how much you have
learnt about how the project uses mechanical and electrical components.

Test: The knowledge you would have had at the start of the project would be very different to the
knowledge you have now so compare it and find out if there is anything you haven’t learnt.

Was I able to work independently or did I have others that helped me throughout the production
process?

Justification: getting other people to help me during the production process, it will not analyse the
way I work independently.

Test: I should get into the habit of working independently and only asking for the teachers help
when needed.

Criteria 2

Detailed research

Arduino nano:

The Arduino Nano is a small, complete, and
breadboard-friendly board based on the
ATmega328. It has more or less the same
functionality of the Arduino Duemilanove,
but in a different package. It lacks only a DC
power jack and works with a Mini-B USB
cable instead of a standard one and the
Arduino nano has a memory capacity of
32KB. The Arduino can be programmed with
a certain software developed by Arduino.

Colour sensor: https://store.arduino.cc/usa/arduino-
nano

The TCS230 TCS3200 colour sensor
works by sensing the colour of the
light with an 8x8 array of
photodiodes. The photodiodes
consist of three different colour
filters. There are 16 red, 16 blue and 16 clear photodiodes with no filters. Each 16 photodiodes are
connected in parallel, so using the two control pins S2 and S3 we can select which of them will be
read. So, for example, if we want to detect red colour, we can just use the 16 red filtered

photodiodes by setting the two
pins to low logic level according
to the table. The sensor has two
more control pins, S0 and S1
which are used for scaling the
output frequency. The frequency
can be scaled to three different
preset values of 100 %, 20 % or
2%. This frequency-scaling
function allows the output of
the sensor to be optimized for
various frequency counters or
microcontrollers.

https://howtomechatronics.com/tutor

Dtiaueltso/sariigradnl-uticonsop2/3ta0iro-dtnucsisn3o2-0c0o-lcoorl-oser-nsseinnsgo-r/

Design option 1: 3D printed case This design will use the 3D printer to create a
Design option 2: plastic case casing for the machine. It will be an
environmentally friendly way to make the case
for the machine.

Positives: If the case is to be 3D printed it
would be able to be made over night which will
remove the manual cutting which will create
more time to work on the rest of the project. It
is a cheap way to create a case.

Negatives: If the production of the case fails
multiple times on the 3D printer it could taken
a long time to get it to print the right way.

This design of the colour sorting machine is made
out of plastic. Although it is not environmentally
friendly it will be reliable for long term usage.

Positives: This design will be able to hold much
more items and it will be able to sort the items
much more faster than any other machine and
because it is made out of plastic, it will last for a
longer time.

Negatives: Although this design can hold more
items, it is very large so it will take up a lot of
space, leaving no room for other objects.

Design option 3: wooden case

This design is made out wood that has been
cut by using the laser cutter. This method of
production is environmentally reliable for the
future.

Positives: This design is much smaller and
compact which is a much better design as it
can be stored in small spaces. By using the
laser cutter to cut the wood, there will be no
problems with the production.

Negatives: Although this product is smaller it
is a little to small. The design ill only be able to hold a small number of items which is not ideal, but
the design is perfect

Final option

The final option will be the 3D printed casing as it is environmentally friendly, and it will be much
easier to make and it will be cheaper to create.

Flow diagram/Modelling and simulating This model/diagram explains
how the electrical components
Arduino nano are connected. Both servo
TCS230 motors will be connected to
TCS3200 both the Arduino nano board
colour sensor and the TCS230 TCS3200
colour sensor and the Arduino
Servo motor nano board will be connected
with TCS230 TCS3200 colour
sensor. With these being
connected together I will be
able to create a smaller casing.

Power supply Switch

https://howtomechatronics.com/wp-content/uploads/2016/07/Arduino-Color-Sorting-Machine-
Circuit-Schematic.png

Criteria 3

Process list

Process Picture Description Purpose
Wire
cutting Removes To make the
pieces of wires
the wire shorter

https://www.ecmag.com/section/your-business/wire-and-
cable-cutters

Wire Removes To remove
stripping the rubber the rubber
on the to expose
outside of the metal
the wires

https://www.selby.com.au/cables/cable-tools/multifunction-
wire-stripper-and-crimper-t1528.html

Soldering Melts metal To connect
to connect wires with
components the Arduino
together components

https://www.woodtoolsanddeco.com/en/soldering-melting-
welding/13513-basic-soldering-iron-30-w-12-meters-cable-
8719762741572.html

Coding Putting To make the
different project
characters function
together to and obey
create a commands
code

https://readwrite.com/2018/04/26/the-problem-with-
believing-coding-is-no-longer-important/

Screwing Tightens or Used to
fastens make the
screws project
secure

http://www.todayifoundout.com/index.php/2014/09/decided-
screws-turn-clockwise/

Electrical Checks the Used to find
testing amount of any
current problems
going with the
through the project
project
https://www.fluke.com/en-
us/product/electrical-testing/digital-multimeters/fluke-179

3D Creates a To create a
printing 3D model of 3D case for
any item the project

https://core-electronics.com.au/creality-ender-3-v2-3d- Descriptio Purpose
printer.html n
To remove
Tools list Removes the rubber
the rubber to expose
Tool Picture on the the metal
outside of
Wire the wires
strippers

https://www.selby.com.au/cables/cable-
tools/multifunction-wire-stripper-and-crimper-
t1528.html

Wire Removes To make
cutters pieces of the wires
the wire shorter

https://www.ecmag.com/section/your-business/wire-
and-cable-cutters

Soldering Melts To connect
iron metal to wires with
connect the
componen Arduino
ts together componen
ts

https://www.woodtoolsanddeco.com/en/soldering-
melting-welding/13513-basic-soldering-iron-30-w-12-
meters-cable-8719762741572.html

3D printer Creates a To create a
3D model 3D case
of any for the
item project

https://core-
electronics.com.au/creality-ender-3-v2-3d-printer.html

Pliers It holds Used to
small take out
items, and bits that
it can are to
remove hard to get
items with hands

https://www.bahco.com/int_en/ergotm-all-round-
pliers-tool-set---4-pcs-pb_9897_.html

screwdriv Tightens Used to
er or fastens make the
screws project
secure

http://www.todayifoundout.com/index.php/2014/09/d
ecided-screws-turn-clockwise/

Soldering Holds Used to
holder items in hold the
place wires as
when an extra
soldering hand
while
soldering

https://www.banggood.com/Hand-Soldering-Iron-
Stand-Helping-Clamp-Magnifying-Tool-Auxiliary-Clip-
Magnifier-Station-Holder-p-
1017105.html?cur_warehouse=CN

Multimet Checks the Used to
er amount of find any
current problems
going with the
through project
the project

https://www.fluke.com/en-us/product/electrical-
testing/digital-multimeters/fluke-179

Components list

Component QTY Picture Purpose Link and price

Arduino 1 To store the codes https://www.banggood.com/Geek
to make the project creit-ATmega328P-Nano-V3-
nano move Module-Improved-Version-With-
USB-Cable-Development-Board-
Geekcreit-for-Arduino-products-
that-work-with-official-Arduino-
boards-p-
933647.html?akmClientCountry=A
U&p=4N130123074053201807&ut
m_campaign=23074053&utm_cont
ent=3312&cur_warehouse=USA
AU$9.62

Servo 2 To make the pieces https://www.banggood.com/SG90-
motor of the project Mini-Gear-Micro-Servo-9g-For-RC-
Airplane-Helicopter-p-
Switch 1 To turn to project on 1009914.html?akmClientCountry=A
and off U&p=4N130123074053201807&ut
Breadboard 1 m_campaign=23074053&utm_cont
To make quick ent=3312&cur_warehouse=AU
TCS230 1 electrical AU$9.26
TCS3200 connections to test
colour https://www.banggood.com/5Pcs-
sensor Used to make the Mini-Round-Black-2-Pin-SPST-ON-
project sense the OFF-Rocker-Switch-Button-p-
colours 946012.html?p=4N1301230740532
01807&utm_campaign=23074053&
utm_content=3312&cur_warehous
e=CN
AU$2.54

https://www.banggood.com/Geek
creit-MB-102-MB102-Solderless-
Breadboard-+-Power-Supply-+-
Jumper-Cable-Kits-p-
933600.html?akmClientCountry=A
U&p=4N130123074053201807&cus
tlixnkid=812509&cur_warehouse=C
N
AU$7.40

https://www.aliexpress.com/item/
32631468847.html?tt=API&af=2049
356_1&utm_campaign=2049356_1
&aff_platform=api-new-link-
generate&utm_medium=cpa&cn=4
6qtwvxskn90oabt2nbie579fa9hym
8r&dp=v5_46qtwvxskn90oabt2nbie
579fa9hym8r&aff_fcid=d54c12b52

Jump wires 14 To connect the aa14cf6a8e7aa7b6ded16d1-
component and to 1622363824397-02585-
Nuts and 10 get a current to flow _lLCTio&cv=39953127&aff_fsk=_lLC
bolts through Tio&product_id=32631468847&sk=
_lLCTio&aff_trace_key=d54c12b52
Used to reinforce aa14cf6a8e7aa7b6ded16d1-
the case 1622363824397-02585-
_lLCTio&terminal_id=258ad09c4cb
b48a2b7c27567080278c8&tmLog=n
ew_Detail&utm_source=epn&utm_
content=39953127
AU$2.94

https://www.banggood.com/Geek
creit-MB-102-MB102-Solderless-
Breadboard-+-Power-Supply-+-
Jumper-Cable-Kits-p-
933600.html?akmClientCountry=A
U&p=4N130123074053201807&cus
tlixnkid=812509&cur_warehouse=C
N
AU$7.40

https://www.bunnings.com.au/syn
eco-bolt-and-nut-hex-set-480-
pieces_p0012909?store=6037
AU$20.00

Risk/hazard assessment

The risk/hazard assessment is conducted in order to eliminate possible dangers that could severely
injure someone. It is also done so that there is also information on how do deal with different types
of risks or hazards and how to prevent them at all times. The table below shows a risk/hazard table
with a sale of 1-20. 1 is the lowest with the potential of an extremely low chance of someone getting
injured whereas 20 is the highest with an extremely high chance of injury or even death.

The second table explains the risks and hazards that could occur when in the workplace and how to
make sure they are prevented with safety control measures.

Hazard

Extremely low Low Moderate High Extremely

high

Extremely low 1 3 6 8 10

Risk Low 3 5 7 10 12

Moderate 6 7 9 11 14

High 8 10 11 16 19

Extremely 10 12 14 19 20

high

Task Identified hazard Overall Rating Safety PPE (personal
3D printer procedures protective
Soldering iron • Fire could Risk-extremely equipment
Always supervise
Wiring be low the machine in • Gloves
case of a • Apron
malfunction and
started if Hazard- wear gloves.

faulty moderate

• Hot Overall-6

plastic

• Burns to Risk-moderate Make sure there • Mask
are open • Soldering
the hands Hazard- windows or
ventilation spots stand
• Inhalation moderate for the fumes • Apron
and ensure that
of the Overall-9 gloves and a • Insulated
mask are worn to gloves
fumes protect from the
heat and fumes. • Insulated
• Fire could tools
Make sure that
be insulated gloves
are worn at all
started times when
dealing with
• Electric Risk-low wires and that
shocks Hazard- there are no
moderate liquids nearby.
• Electric Overall-7
burns

Gantt chart

Onguard certificates



Production record

The start of the production had to be delayed
due to the current COVID-19 situation that
has impacted the research and the product
process of the project. The construction of
the project had to be commenced at a much
later date due to certain materials and tools
being left at the school.

However, the main component that I was unable to receive by the end of the production process
was the colour sensor, all other items were collected to put together what could be done.

The first step of the production process was to clip the
rubber around the wire to expose the copper wires
underneath the rubber to be soldered. This process
had to be done with wire strippers in order to strip the
rubber away and this was to be done to all of the
wires used in the project.

The next step of the design process was to solder all of
the wires together and connect and solder the wires
to the Arduino nano and the colour sensor however
there was no colour sensor to solder the wires to. The
tools used to do this was a soldering iron, solder, and
a soldering stand and this has been done to create a
connection so that the electricity can flow through the
circuit and bring power to the project.

Once all of the wires and the other components
of the design have been soldered together the
casing of the product was needed to be made.
The original design of the casing was to be made
by using the 3D printer however because the
project had to be built at home due to the
COVID-19 situation. Instead the project had to be
built by using cardboard.

After the casing has been completed, the final
stage of the construction is to stick on the
different components into the case. One servo
motor was placed on the bottom shelf and the
second servo motor was placed on the top shelf
and each motor is programmed to do different
things.

Due to the colour sensor not arriving in time for the project a replica was made out of cardboard.

Final product

The image below shows what the final product is
meant to look like. Due to the current
circumstances regarding COVID-19, the case for
the whole project was not able to be 3D printed
because of the lack of access to a 3D printer which
means that the case had to be made out of
cardboard. Unfortunately, the main component of
the whole project, the colour sensor, did not arrive
due to the COVID-19 situation, so the colour
sensor was also made out of cardboard, which
means that the final product was not able to
function. Luckily enough, all of the other
components such as the servo and the Arduino nano had been collected at school before the
lockdown so nearly all of the project was to be built.

Test

Due to some of the components being unable to arrive especially the main component, (the colour
sensor), a test was not able to be conducted.

Evaluation criteria

(Based off of criteria 1)
Project evaluation:
Below is the evaluation questions from criteria 1 with a full evaluation of the final product. Due to
the COVID-19 situation some of the main components did not arrive, because of this not all of the
questions will be answered very well.
Does the product look aesthetically attractive and does it suit the environment it will be placed in?
Due to the case and the main component not being able to arriv eon time because of COVID-19, the
case and the component had to be made out of cardboard which does not give the project an
aesthetic look.
Have there been any problems with the components of the project?
Yes, the only problem there was, was that the main component (the colour sensor) did not arrive
which caused the final product to not function and fulfil its purpose.
During the production process, were there any changes that were made to the project?
Yes, during the production process the only changes that were made was the casing of the project
and the component.
Does the product fulfill its original purpose?
Due to the final product missing its main component, the project was unable to fulfil its intended
purpose of a colour sorting machine.
Does the project have any safety hazards that should be addressed?
No, the project has no safety hazards that need to be addressed.

Self-evaluation:
Was I able to prevent any accident while building the project? Where there any accidents?
Yes, I was able to prevent all different types of accident from occurring and because eof this there
were no accidents that occurred.
How well was I able to control any hazard or danger to avoid any injuries? Was I able to avoid any
distractions that could’ve caused injuries?

Yes, I was able to avoid any dangerous situation that could have put my life in danger. While
constructing the final project, all the correct PPE was worn in order to prevent any injuries form
occurring.

Were you able to overcome any difficult stages of the project?

Yes, because of the current COVID-19 situation, I was unable to complete my project however I
found a solution that helped me in finishing my project. There was also a slight problem with the
soldering however the problem was resolved very quickly.

Would you say that you have gained a reasonable amount of knowledge while building this project?

I can say that I have gained quite an amount of knowledge while constructing my project and a lot
more knowledge during the research stage.

Was I able to work independently or did I have others that helped me throughout the production
process?

I was able to work independently throughout the whole design process and manufacturing process.

Evaluation of the engineering process

Define the problem

The problem was obviously defined in the first criteria of the design brief and every step of the
design process has been clearly linked back to the original problem which gave the designer a clear
understanding of each stage.

Generate possible solutions

Multiple solutions for the end-users problem were found. Many different ideas and solutions for the
intended problem have been researched with great depth.

Evaluate possible solutions

The chosen solution was evaluated very carefully to make suer that the chosen design of the project
fulfils all of the end-users constraints and considerations. More research was made in order to come
to a decision on this design. Depth research and detailed research was conducted in order to figure
out the different subsystems that the product needed.

Plan and make the model

I was able to think of, plan and create a suitable product for the end-user that would also fulfil the
original problem. Although the production of the project was mean to happen earlier in the year, the
production was made to be pushed back due to COVID-19 situations. Because of this time
management had become an issue as the project had to be bult at home.

Test, modify and improve the design

I was able to act immediately and effectively when modifications were needed to be made on the
final project. The only problem that occurred was some of the components not being able to arrive
due to the circumstances of the year, however in the future the project will improve greatly with
much more time to construct.

Evaluate final product
The final evaluation of the project was done with care and a fair view on the project. Each part of the
evaluation was broken into different sections to evaluate the different parts of the project.

References

• https://medium.com/swlh/ipo-diagram-with-r-
22bbe186b95d#:~:text=An%20IPO%20(Input%2DProcess%2D,after%20a%20set%20of%20op
erations.

• https://www.instructables.com/Breadboard-How-
To/#:~:text=The%20purpose%20of%20the%20breadboard,electrically%20connected%20to%
20each%20other.

• https://howtomechatronics.com/tutorials/arduino/arduino-color-sensing-tutorial-tcs230-
tcs3200-color-sensor/

• https://howtomechatronics.com/projects/arduino-color-sorter-project/

• https://www.metakcolorsorter.com/color-sorter-machine/plastic-color-sorter

• https://www.cnet.com/news/3d-printed-machine-sorts-skittles-by-colour/

• https://www.arduino.cc/en/pmwiki.php?n=Main/ArduinoBoardNano

• https://store.arduino.cc/usa/arduino-nano