Sarcouncil Journal of Applied Sciences Aims & Scope

Abstract: Automatic conveyor systems are essential for material handling in modern manufacturing, yet conventional implementations commonly run continuously under timer control or single-sensor triggering. Such operation wastes electrical energy and accelerates mechanical wear whenever the conveyor line is unloaded. This paper presents the design and implementation of an Arduino Uno–based automatic conveyor control system that employs a counter-based logic strategy. Two NPN photoelectric sensors are installed at the entry and exit of the conveyor to count incoming and outgoing objects in real time; the drive motor is energized only while the number of objects that have entered exceeds the number that have exited, and it stops automatically once the line is empty. A relay module electrically isolates the 12 V DC motor from the microcontroller, and a hard-wired emergency stop provides an independent safety layer. The belt speed was analyzed to guarantee that each object dwells within the sensing zone longer than the sensor response time, ensuring reliable detection. Experimental testing shows that the sensors detect objects accurately within their effective range and that the counter logic regulates motor operation strictly according to load presence. The proposed system improves operational efficiency, reduces unnecessary energy consumption, and mitigates no-load mechanical wear, thereby supporting a more intelligent industrial automation process.