3D Printed Hardware Sorter Keeps It Simple

November 2, 2024 by Dan Maloney 8 Comments

If you’re like us, you’ve got at least one bin dedicated to keeping the random hardware you just can’t bear to part with. In our case it’s mostly populated with the nuts and bolts left over after finishing up a car repair, but however it gets filled, it’s a mess. The degree to which you can tolerate this mess will vary, but for [EmGi], even a moderately untidy pile of bolts was enough to spur this entirely 3D-printed mechanical bolt sorter.

The elements of this machine bear a strong resemblance to a lot of the sorting mechanisms we’ve seen used on automated manufacturing and assembly lines. The process starts with a hopper full of M3 cap head bolts of varying lengths, which are collated by a pair of elevating platforms. These line up the bolts and lift them onto a slotted feed ramp, which lets them dangle by their heads and pushes them into a fixture that moves them through a 90° arc and presents them to a long sorting ramp. The ramp has a series of increasingly longer slots; bolts roll right over the slots until they find the right slot, where they fall into a bin below. Nuts can also feed through the process and get sorted into their own bin.

What we like about [EmGi]’s design is its simplicity. There are no motors, bearings, springs, or other hardware — except for the hardware you’re sorting, of course. The entire machine is manually powered, so you can just grab a handful of hardware and start sorting. True, it can only sort M3 cap head bolts, but we suspect the design could be modified easily for other sizes and styles of fasteners. Check it out in action in the video below.

Just because it’s simple doesn’t mean we don’t like more complicated hardware sorters, like the ones [Christopher Helmke] builds.

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Automatic Nut Sorter For A Tidy Workspace

August 23, 2021 by Al Williams 28 Comments

We all have that one drawer or box full of random hardware. You don’t want to get rid of anything because as soon as you do, that’s the one thing you’ll need. But, honestly, you’ll be lucky to find what you need in there, anyway. Enter [Mr. Innovative’s] nut sorting machine. As you can see in the video below, it will make order out of the chaos, at least for nuts.

You might think the device would need optical recognition software or some other high-tech mechanism. But, in fact, it is nothing more than a motor with a speed controller. The sorting is done by a plastic piece built like stairs. When a nut is too tall to fit under the next step, it slides out into the output hopper. You could probably turn the whole thing with a crank and no electricity at all if you wanted to.

Drilling out the shaft required a bit of machine tool usage, so this might not be a great weekend project without a lathe. Like many of the commenters on the video mentioned, we probably wouldn’t have used a rod holder as a rotating bearing, either, but for as little as something like this would probably operate, it is likely to last a fair amount of time. It would be easy to replace it or even affix a shaft to the motor with a coupler, sidestepping several issues.

Apparently, the device isn’t perfect. You do get some missorts. We imagine that’s from a larger nut pushing a smaller nut on the way to the hopper. The Thingiverse files seem to be missing, but this is something you’d probably adapt to your own design, anyway.

It isn’t as automated, but we’ve seen a gadget that can help sort drill bits, too. Sometimes you want to sort little parts by color, too.

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Sorting Thousands Of Drill Bits

November 17, 2020 by Mike Szczys 42 Comments

[Austin Adee] came into some drill bits. A lot of them actually. But when thousands of assorted sizes are delivered in one disorganized box, are they actually useful? Not unless you’re drilling holes where diameter doesn’t matter.

So two projects were at hand: finding a place to store a few hundred different sizes of bits, and tackling the actual sorting itself. In the end, he used input from a digital caliper alongside a Python script that showed him where to put them.

The start of the tray design process was a bit of a research project, establishing the common sizes and how many would fit into a given space. This data was used to spin up the layout for trays with 244 different pockets to hold the bits. The pockets were CNC milled, but getting labels for each to work with the laser engraver was a bit of a hack. In the end, filling in the letters with white crayon really makes them pop, despite [Austin’s] dissatisfaction with the level of contrast.

But wait, we promised you an epic sorting hack! Unfortunately there’s no hopper, vibration feed, and sorting gantry that did this for him (now if it were perler beads he’d have been all set). Still, the solution was still quite a clever one.

A set of digital calipers with a Bluetooth connection sends the dimension back to a python script every time you press the capture button. That script find the pocket for the nearest size and then highlights it on a map of the drill bit drawer displayed on the computer monitor. In the end the trays fit into a wide tool chest drawer, and are likely to keep things organized through exactly one project before everything is once again in disarray.

[Austin] mentions a lag of up to one second for the Bluetooth calipers to do their thing. For assembly-line style work, that adds up. We remember seeing a really snappy reaction time on these digital calipers hacked for wireless entry.

Lego Machine Uses Machine Learning To Sort Itself Out

December 16, 2019 by Dan Maloney 8 Comments

In our opinion, the primary evidence of a properly lived childhood is an enormous box of every conceivable Lego piece, from simple bricks to girders and gears, all with a small town’s worth of minifigs swimming through it. It takes years of birthdays and Christmases to accumulate a Lego collection best measured by the pound, but like anything worth doing, it’s worth overdoing.

But what to do with such a collection? Digging through it to find Just the Right Piece™ can be frustrating, and bringing order to the chaos with manual sorting is just so impractical. How about putting some of those bricks to work with a machine-vision Lego sorter built from Lego?

[Daniel West]’s approach is hardly new – we’ve even featured brick-built Lego sorters before – but we’re impressed by its architecture. First, the mechanical system is amazing. It uses a series of conveyors to transport bricks from a hopper, winnowing the stream down as it goes. The final step is a vibratory feeder that places one piece on a conveyor at a time. Those pass under a camera attached to a Raspberry Pi, where OpenCV does background subtraction from the video stream, applies bounding boxes to the parts, and runs the images through a convolutional neural network (CNN) that’s been trained on a database of every Lego part. Servo-controlled gates then direct the parts into one of 18 bins. See it in action in the video below.

We must admit that we’re not sure what the sorting criteria are, as some bins seem nearly as chaotic as the input mix. Still, we appreciate the fine engineering, and award extra style points for all the Lego goodness.

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Paint The Rainbow With This Skittle-Dropping Pixel Art Robot

July 12, 2019 by Dan Maloney 7 Comments

We hackers just can’t get enough of sorters for confections like Skittles and M&Ms, the latter clearly being the superior candy in terms of both sorting and snackability. Sorting isn’t just about taking a hopper of every color and making neat monochromatic piles, though. [JohnO3] noticed that all those colorful candies would make dandy pixel art, so he built a bot to build up images a Skittle at a time.

Dubbed the “Pixel8R” after the eight colors in a regulation bag of Skittles, the machine is a largish affair with hoppers for each color up top and a “canvas” below with Skittle-sized channels and a clear acrylic cover. The hoppers each have a rotating disc with a hole to meter a single Skittle at a time into a funnel which is connected to a tube that moves along the top of the canvas one column at a time. [JohnO3] has developed a software toolchain to go from image files to Skittles using GIMP and a Python script, and the image builds up a row at a time until 2,760 Skittle-pixels have been placed.

The downside: sorting the Skittles into the hoppers. [JohnO3] does this manually now, but we’d love to see a sorter like this one sitting up above the hoppers. Or, he could switch to M&Ms and order single color bags. But where’s the fun in that?

[via r/arduino]

Robot Sorts Beads By Color

October 7, 2018 by Al Williams 29 Comments

If you know anyone who does crafts, they probably have a drawer with a few million beads loose and mixed together. You’ll sort them out one day, right? Probably not. Unless, of course, you build a robot to do the dirty work for you. That’s what [Kalfalfa] did, using some Phidgets boards, a camera and Open CV. You can see a video of the cardboard machine doing its thing below.

Maybe it is because we are more electronics-minded, but we were impressed with the mechanism to grab just one bead at a time from the hopper. If you watch the video, you’ll see what we mean. However, sometimes a bead jams and a magnetic sensor figures that out so the controller can reverse a bit and try again.

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Automated Parts Counter Helps Build A Small Business

April 21, 2017 by Dan Maloney 28 Comments

We love to see projects undertaken for the pure joy of building something new, but to be honest those builds are a dime a dozen around here. So when we see a great build that also aims to enhance productivity and push an entrepreneurial effort along, like this automated small parts counter, we sit up and take notice.

The necessity that birthed this invention is [Ryan Bates’] business of building DIY arcade game kits. The mini consoles seen in the video below are pretty slick, but kitting the nuts, bolts, spacers, and other bits together to ship out orders was an exercise in tedium. Sure, parts counting scales are a thing, but that’s hardly a walk-away solution. So with the help of some laser-cut gears and a couple of steppers, [Ryan] built a pretty capable little parts counter.

The interchangeable feed gears have holes sized to move specific parts up from a hopper to a chute. A photointerrupter counts the parts as they fall into plastic cups on an 8-position carousel, ready for bagging. [Ryan] also has a manual counter for wire crimp connectors that’s just begging to be automated, and we can see plenty of ways to leverage both solutions as he builds out his kitting system.

While we’ve seen more than a few candy sorting machines lately, it’s great to see someone building hardware to streamline the move from hobby to business like this. We’re looking forward to seeing where [Ryan] takes this from here.

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