PackSort
No Thumbnail Available
Date
2026
Authors
Baker Razi Wael Yaeesh
Mohammad Maher Mohammad Himuni
Journal Title
Journal ISSN
Volume Title
Publisher
Abstract
This project presents the design and implementation of an intelligent automated sorting system
capable of categorizing packages based on multiple parameters including barcode data, color,
and physical dimensions. The system integrates an Arduino Mega as the central processing unit
with a specialized Arduino Uno for barcode processing, creating a robust distributed control
architecture.
The sorting mechanism employs a conveyor belt powered by a DC wiper motor controlled
through a BTS7960 driver module, with package diversion accomplished using servo-actuated
pusher arms. Detection subsystems include an omnidirectional barcode scanner for package
identification, TCS3200 color sensors for color recognition, ultrasonic sensors for dimensional
analysis, and IR sensors for position tracking.
A significant feature of this system is its flexible multi-mode operation, allowing sorting based
on seven different criteria combinations: size alone, color alone, barcode alone, color and size,
barcode and color, barcode and size, or all three parameters simultaneously. The system
incorporates multiple fail-safes including an emergency stop button and comprehensive error
handling protocols.
For power efficiency, the system also includes an automatic shut-off feature: if no packages are
detected on the conveyor for 2 minutes, the system powers down automatically until new
activity is detected.
Human-machine interface is provided through a keypad and LCD display for local control, while
an ESP32 microcontroller enables wireless connectivity for remote monitoring and operation via
a custom-developed Flutter mobile application. This mobile interface provides real-time
package statistics and system status updates, enhancing operational visibility.
This automated sorting solution demonstrates significant improvements in efficiency and
accuracy over manual sorting methods, with potential applications in logistics centers, postal
services, and industrial packaging facilities. The modular design allows for adaptation to various
sorting criteria and operational requirements, making it a versatile solution for modern package
handling challenges.