ABSTRACT

The Mentioned project is based on the worlds most powerful Intel controller 8051. Most of the services provided in todays world are voice interactive, you call up your bank and computerized voice will speak to you, and guide you to enter a particular number from your phone to get the desired service. This service is only available through the fast speed computers and having huge amount of memory. We implemented interactive service for industrial applications. You can switch on/off devices using your mobile phone or land line phone eight numbers loads can be connected to the eight relay provided. Not only you can switch on /off devices it will also dial out a telephone number in case of security threat or any safety or protection parameters goes beyond safety limit. This project could be used to control or switch on any process control machinery where all functions are automatic. Electric grid could be controlled remotely. Or automatic production machinery could be controlled even during odd hours with your mobile phone. SAFETY FEATURES OF THIS SYSTEM:Suppose there is fire at the machinery space; this device will switch off the machinery first and then make an emergency call on your phone. The device will make five emergency calls at the interval of one minute and again monitor for the previous status. If the smoke have subsided then the device will not call further, otherwise it will make another 5 calls. In case of any of the above, for ex. temperature of the machinery has gone beyond safety limit, the device will first switch off the plant and dials out the presorted telephone number and delivers the emergency message. It will dial out foe five times at the interval of one minute and again monitor the parameters, and if the parameters are not within limit again it will dial out. This cycle will repeat until the parameters become normal.

INDEX
1. INTRODUCTION:-...................................................................................1
1.1 HISTORY:-......................................................................................................................1 1.2 CURRENT SCENARIO:- ...............................................................................................2

2. VARIOUS METHODS FOR IMPLEMENTATION:-..................................3 3. BLOCK DIAGRAM:-........................................................................... 4

3.1 TELEPHONE CONNECTION:- .....................................................................................5 3.2 RING DETECTOR CIRCUIT:- ......................................................................................6 3.2.1 BRIDGE RECTIFIER CIRCUIT: - ..............................................................................6 3.2.2 OPTOCOUPLER IC MCT2E:- ....................................................................................6 3.3 WATCH TIMER IC 4047 AND NAND GATE IC 7400:- .............................................7 3.3.1 IC 7400 (NAND GATE):- ..........................................................................................10 3.4 DTMF DECODER IC 8870:- ........................................................................................10 3.5 OFF-HOOK RELAY OPERATION:-...........................................................................12 3.6 AUTO DIALING RELAY:- ..........................................................................................16 3.7 MICROCONTROLLER 89C51:-..................................................................................16 3.8 SPEECH CIRCUIT IC AP89042:- ................................................................................19 3.9 AMPLIFIER CIRCUIT IC LM386:- .............................................................................21 3.10 SERIAL EPROM IC 93C46:-......................................................................................22 3.11 POWER SUPPLY CIRCUIT IC 7805:- ......................................................................23 3.12 SENSOR:-....................................................................................................................23 3.13 ALGORITHM/FLOWCHART:- .................................................................................24

4. CIRCUIT DIAGRAM:-...............................................................................25
4.1 DETAILED CIRCUIT DISCRIPTION:- ......................................................................26 4.2 OPERATION:- ..............................................................................................................30 4.2.1 NORMAL ON /OFF MODE:-....................................................................................30 4.2.2 PASSWORD CHANGE:-...........................................................................................31 4.2.3 TELEPHONE NUMBER CHANGE:- .......................................................................31

5. APPLICATION AND FUTURE EXTENSION:-........................................32

5.1 APPLICATION:- ......................................................................................................32

5.2 FUTURE EXTENSION:- ..............................................................................................32

6. CONCLUSION:-..............33
6.1 6.2 ADVANTAGES:- .....................................................................................................33 DISADVANTAGES:-...............................................................................................33

7. APPENDIX:-............................................................................................34
PCB LAYOUT..............................................................................................................34 LIST OF COMPONENTS:- .........................................................................................35 BILL OF MATERIALS................................................................................................36 WORK PHOTOGRAPHS ............................................................................................39 REFRENCES................................................................................................................41

LIST OF FIGURE
Figure 3.1 BLOCK DIAGRAM OF IVRS SYSTEM ...............................................................4 Figure3.2 TELEPHONE LINE WITH ADSL SPLITTER........................................................5 Figure 3.3 BRIDGE RECTIFIER ..............................................................................................6 Figure 3.4 OPTOCOUPLER IC MCT2E ..................................................................................6 Figure 3.5 WATCHDOG TIMER IC HEF4047B .....................................................................7 Figure 3.6 FUNCTIONAL BLOCK DIAGRAM OF WATCHDOG TIMER IC .....................8 Figure 3.7 NAND GATE IC 7400...........................................................................................10 Figure 3.8 PIN DIAGRAM OF DTMF DECODER IC 8870 ................................................10 Figure 3.9 BASIC CALL PROCESS: ON-HOOK.................................................................13 Figure 3.10 BASIC CALL PROCESS: OFF-HOOK ..............................................................13 Figure 3.11 BASIC CALL PROCESS: DIALING..................................................................14 Figure 3.12 BASIC CALL PROCESS: SWITCHING ...........................................................14 Figure 3.13 BASIC CALL PROCESS: RINGING ................................................................15 Figure 3.14 BASIC CALL PROCESS: TALKING................................................................15 Figure 3.15 MICROCONTROLLER IC 89C51.....................................................................16 Figure 3.16 SPEECH IC AP89042 ..........................................................................................19 Figure 3.17 AMPLIFIER CIRCUIT IC LM386 .......................................................................21 Figure 3.18 LM386 DRIVER SPEAKER.................................................................................21 Figure 3.19 VOLTAGE REGULATOR IC 7805.....................................................23 Figure 3.20 VOLTAGE REGULATOR IC 7805 ....................................................................23 Figure 3.21 POWER SUPPLY CIRCUIT ...............................................................................23

Figure 3.22 FLOW CHART ....................................................................................................24 Figure 4.1 CIRCUIT DIAGRAM OF IVRS SYSTEM...........................................25 Figure 7.1 PCB LAYOUT OF IVRS SYSTEM...........................................34

LIST OF TABLE
Table 3.1 KEY TONE AND OUTPUT LOGIC OF IC 8870..................................................11 Table 3.2 PIN DESCRIPTION OF PORT 3 OF MICROCONTROLLER IC 89C51 ............18 Table 3.3 IC 93C46 PIN NUMBER AND DESCRIPTION22 Table 7.1 LIST OF COMPONENT .........................................................................................35 Table 7.1 BILL OF MATERIALS...........................................................................................36

INTRODUCTION

1. INTRODUCTION:1.1 HISTORY:Research in speech technology predated the advent of digital computers. It began with a speech synthesis project at Bell Labs in 1936 that resulted in a device called "The Voder" which was demonstrated at the 1939 Worlds Fair. In 1961, Bell System developed a new tone dialing methodology. Bell unveiled the first telephone that could dial area codes using DTMF technology at the Seattle World Fair in 1962. DTMF telephones enabled the use of in-band signaling, i.e., they transmit audible tones in the same 300 Hz to 3.4 KHz range occupied by the human voice. The blueprint for IVR was born. Despite the increase in deployment of IVR technology in the 1970s to automate tasks in call centers, the technology was still complex and expensive. Early speech recognition systems were DSP technology based, and were limited to small vocabularies. However, by the 1980s a number of new competitors entered the market and uptake of IVR technology started to increase. As speech recognition software developed the technology changed from DSP to a client/server architecture. As call centers began to migrate to multimedia in the late 1990s, companies started to invest in Computer Telephony Integration (CTI) with IVR systems. IVR became vital for call centers deploying universal queuing and routing solutions and acted as an agent which collected customer data to enable intelligent routing decisions. In the subsequent decade, speech recognition started to become more common and cheaper to deploy. This was due to increased CPU power.

Page 1

INTRODUCTION

1.2 CURRENT SCENARIO:This is live project .In HBI PLANT, there are four furnace for prepare hot briquetted sponge iron in these furnace. They melt raw material of steel at 1200c. During this process, there is variation in temperature. It is necessary to maintain temperature or to control the temperature. This project help them to when the temperature is goes beyond the limit, this system inform them and call the authorized person automatically and call them till the system become normal. We are also control pressure and smoke by using pressure and smoke sensor. They also on/off the channel using this system and using this system, they also know the status of the channel. Now a days other common IVR services include:

Mobile Pay-As-You-Go account funding; registration; mobile purchases, such as ring tones and logos Banking balance, payments, transfers, transaction history Retail & Entertainment orders, bookings, credit & debit card payments Travel ticket booking, flight information, check-in Weather forecasts, water, road and ice condition

IVR systems are typically used to service high call volumes, reduce cost and improve the customer experience. Examples of typical IVR applications are telephone banking, televoting, and credit card services. Companies also use IVR services to extend their business hours to 24/7 operation. Call centers use IVR systems to identify and segment callers. The ability to identify customers allows services to be tailored according to the customer profile. The caller can be given the option to wait in the queue, choose an automated service, or request a callback (at a suitable time and telephone number). The system may obtain caller line identification (CLI) data from the network to help identify or authenticate the caller. This is currently available for about 80% of inbound calls Additional caller authentication data could include account number, personal information, password and biometrics (such as voice print).

Page 2

VARIOUS METHODS FOR IMPLEMENTATION

2. VARIOUS METHODS FOR IMPLEMENTATION:We can implement this project by using various methods as below: 1. By using mobile phone:In our project we use land line phone this project will also implement by using mobile phone. By use of mobile phone, complexity of circuit is less. But tower problem and battery problem is occur in mobile handset. So we use landline telephone. 2. Device control through PC:In this system device is on/off by using the pc, but this system is used for only short distance and it provide less mobility then IVRS system. 3. Device control using landline without IVRS system:In this project IVRS system is not used so we can not interact with the system easily, but only switch on/off the devices using this system. And also it not provides the safety and security for the device. 4. Device control using landline with IVRS system:Now by using the landline with IVRS system we can control device from anywhere and it provide safety as well as security. Technology Used By IVRS:DTMF decoding and speech recognition are used to interpret the caller's response to voice prompts. DTMF tones are entered via the telephone keypad. Other technologies include using Text-To-Speech (TTS) to speak complex and dynamic information, such as e-mails, news reports or weather information. TTS is computer generated synthesized speech that is no longer the robotic voice traditionally associated with computers. Real voices create the speech in fragments that are spliced together (concatenated) and smoothed before being played to the caller.

Page 3

BLOCK DIAGRAM

3. BLOCK DIAGRAM:RELAY 1 DRIVER CIRCUIT RING DETECTOR RELAY 2 RELAY 3 RELAY 4 RELAY 5

TEL

WDT

OFF-HOOK CIRCUIT

8051 MICRO CONTROLLER

SERIAL EPROM

DTMF DECODER SPEECH IC AUTO DIALER

AMPLIFIRE

SPK

SENSORS

Figure 3.1 BLOCK DIAGRAM OF IVRS SYSTEM

Page 4

BLOCK DIAGRAM

PROJECT HAS THE FOLLOWING BLOCKS: Telephone connection Ring detector circuit comprise of bridge rectifier and optocoupler IC MCT2E Watchdog timer IC 4047 comprise of IC 7400(NAND GATE) DTMF decoder IC 8870 Off-hook relay Auto dialing relay Microcontroller AT89C51 Speech circuit IC AP89042, where all the messages are stored Amplifier circuit IC LM386 Serial EPROM IC AT93C46 Power supply circuit IC 7805 Sensor 3.1 TELEPHONE CONNECTION:-

Figure3.2 TELEPHONE LINE WITH ADSL SPLITTER We are use fixed telephone Connection. In this telephone, there are two ports. One for main connection and other for data input/output port. In this second port, we connect our connector of the system. We can give input to our system using this port through our telephone or mobile and also receive response of our system. ADSL splitter is used to split the main telephone line in to two different line, one for telephone and another for the circuit of IVRS system.

Page 5

BLOCK DIAGRAM

3.2 RING DETECTOR CIRCUIT:It detects ringing signal using following circuit:3.2.1 Bridge rectifier circuit 3.2.2 Optocoupler 3.2.1 BRIDGE RECTIFIER CIRCUIT: -

Figure 3.3 BRIDGE RECTIFIER Bridge rectifier is an arrangement of four diodes in a bridge configuration that provides same polarity of o/p voltage for either polarity of I/p voltage. Ringing signal is around 70v to 75v is rectified by the bridge rectifier circuit. For most common application, it is used for conversion of a.c I/p into d.c o/p, it is known as bridge rectifier. 3.2.2 OPTOCOUPLER IC MCT2E:-

Figure 3.4 OPTOCOUPLER IC MCT2E

Page 6

BLOCK DIAGRAM

Optocoupler or optoisolator is a device that uses a short optical transmission path to transfer a signal between element of circuit, typically transmitter and receiver, while keeping them electrically isolated, since the signal goes from electrical signal to optical signal and back to electric signal, electric contact along the path is broken. With the ringing signal, LED inside the optocoupler will glow and light will fall on the base of the transistor. Emitter is connected to ground. 3.3 WATCH TIMER IC 4047 AND NAND GATE IC 7400:-

Figure 3.5 WATCHDOG TIMER IC HEF4047B The watchdog timer is an IC that monitors the microcontroller, and resets it when running away. Ricoh watchdog timers are implemented with the voltage detector; therefore, they can reset the microcontroller by the detection dropping of the voltage. Astable operation is enabled by a HIGH level on the ASTABLE input. The period of the square wave at O and O outputs is a function of the external components employed. True input pulses on the ASTABLE or complement pulses on the ASTABLE input, allow the circuit to be used as a gatable multivibrator. The OSCILLATOR OUTPUT period will be half of the O output in the astable mode. However, a 50% duty factor is not guaranteed at this output.

Page 7

BLOCK DIAGRAM

In the monostable mode, positive edge-triggering is accomplished by applying a leading-edge pulse to the + TRIGGER input and a LOW level to the TRIGGER input. For negative edge-triggering, a trailing-edge pulse is applied to the TRIGGER and a HIGH level to the + TRIGGER. Input pulses may be of any duration relative to the output pulse. The multivibrator can be retriggered (on the leading-edge only) by applying a common pulse to both the RETRIGGER and + TRIGGER inputs. In this mode the output pulse remains HIGH as long as the input pulse period is shorter than the period determined by the RC components. An external count down option can be implemented by coupling O to an external N counter and resetting the counter with the trigger pulse. The counter output pulse is fed back to the ASTABLE input and has a duration equal to N times the period of the multivibrator. A HIGH level on the MR input assures no output pulse during an ON-power condition. This input can also be activated to terminate the output pulse at any time. In the monostable mode, a HIGH level or power-ON reset pulse must be applied to MR, whenever VDD is applied.

Figure 3.6 FUNCTIONAL BLOCK DIAGRAM OF WATCHDOG TIMER IC

Page 8

BLOCK DIAGRAM

Input includes + TRIGGER, -TRIGGER, ASTABLE ,ASTABLE ,RETRIGGER and MR (Master reset).Buffered output are O, , And OSCILLATOR OUTPUT, in all modes of operation an external capacitor (Ct) must be connected CTC and RCTC, and external resistor (Rt) must be connected between RTC and RCTC. General features: Monostable (one-shot) or astable (free-running) operation True and complemented buffered outputs Only one external R and C required Monostable multivibrator features: Positive- or negative-edge triggering Output pulse width independent of trigger pulse duration Retriggerable option for pulse-width expansion Long pulse width possible using small RC components by means of external counter provision Fast recovery time essentially independent of pulse width Pulse-width accuracy maintained at duty cycles approaching 100% Astable multivibrator features: Free-running or gatable operating modes 50% duty cycle Oscillator output available

Page 9

BLOCK DIAGRAM

3.3.1 IC 7400 (NAND GATE):-

Figure 3.7 NAND GATE IC 7400 It is also called inverter IC, it converts low I/p into high o/p and vice versa. It is two I/p and one o/p ic. It supports IC 4047 that is watchdog timer IC. When bell rings, collector of the optocoupler IC will go low is connected to pin no 12 and pin no 13 of the IC 7400 and NAND gate IC o/p at pin no 11 become high is connected to pin no 8 and pin no 12 of the watchdog timer IC. So pin no 10 of watchdog timer IC will go high and it become communication on. 3.4 DTMF DECODER IC 8870:-

Figure 3.8 PIN DIAGRAM OF DTMF DECODER IC 8870 This circuit detects the dial tone from a telephone line and decodes the keypad pressed on the remote telephone.

Page 10

BLOCK DIAGRAM

The dial tone we heard when we pick up the phone set is call Dual Tone MultiFrequency, DTMF in short. The name was given because the tone that we heard over the phone is actually make up of two distinct frequency tone, hence the name dual tone. The DTMF tone is a form of one way communication between the dialer and the telephone exchange. The 8870 is a full DTMF receiver that integrates both band split filter and decoder functions into a single 18- pin DIP or SOIC package. Manufactured using CMOS process technology, the 8870 offers low power consumption (35mW max) and precise data handling. Its filter section uses switched capacitor technology for both the high and low group filters and for dial tone rejection. Its decoder uses digital uses digital counting techniques to detect and decode all 16 DTMF tone pairs into a 4-bit code. 4-bir code o/p is available at pin no 11, 12, 13, 14(q1 to q4). Every new byte available on these four pins will be indicated by a low going pulse at pin no 15 of this IC Detection of dial tones is reflected on the bit TOE, while the output Q4 , Q3 , Q2 , Q1 indicate the dial tone that is being detected on the telephony system. A complete table of the decoded digital output for individual dial tone is available in the coming section OUTPUT LOGIC Q3 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0

Key tone 1 2 3 4 5 6 7 8 9 0 * # A B C D

Q4 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0

Q2 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0

Q1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0

Table 3.1 KEY TONE AND OUTPUT LOGIC OF IC 8870 Page 11

BLOCK DIAGRAM

Features: Low power consumption Adjustable Acquisition and Release Times Central Office Quality and Performance Power-down and Inhibit Modes Inexpensive 3.58MHz time base Single 5 volt power supply Dial Tone Suppression Application: Telephone switch equipment Remote data entry Paging systems Personal computers 3.5 OFF-HOOK RELAY OPERATION:Before making any call, we need to lift up the handset, this process is known as offhook. To understand off-hook operation, first we need to study basic call progress. Basic call progress is divided into six phases: ON-HOOK OFF-HOOK DIALING RINGING TALKING

Page 12

BLOCK DIAGRAM

Now we discuss all the six phases with the help of figure

Figure 3.9 BASIC CALL PROCESS: ON-HOOK When the handset resets on the cradle, circuit is on-hook. In other words, before a phone call is initiated, the telephone set is in a ready condition waiting for a caller to pick up its handset. This state is called on-hook. In this state, the 48v D.C. circuit from the telephone set to the CO switch is open. The CO switch contains the power supply for this DC circuit. The power supply located at the CO switch prevents a loss of telephone service when the power goes out at the location of the telephone set. Only the ringer is active when the telephone is in this position.

Figure 3.10 BASIC CALL PROCESS: OFF-HOOK The off-hook phase occurs when the telephone customer decides to make a phone call and lifts the handset from the telephone cradle. The switch hook closes the loop between the CO switch and the telephone set and allows current to flow. The CO switch detects this current flow and transmits a dial tone (350 and 440hertz [Hz] tones played continuously) to the telephone set. This dial tone signals the customer can begin to dial. There is no guarantee that the customer could have to wait for a dial tone. The access capacity of the CO switch used determines how soon a dial tone only after the switch has reserved registers to store the incoming address. Therefore, the customer cannot dial until a dial tone is received. If there is no dial tone, then the registers are not available.

Page 13

BLOCK DIAGRAM

Figure 3.11 BASIC CALL PROCESS: DIALING The dialing phase allows the customer to enter a phone number of a telephone at another location. The customer enters this number with either a rotary phone that generates pulses or a touch-tone phone that generates tones. These telephones use two different types of address signaling in order to notify the telephone company where a subscriber calls: dual tone multi frequency (DTMF) dialing and pulse dialing. These pulses or tones are transmitted to the CO switch across a two-wire twisted-pair cable (tip and ring lines).

Figure 3.12 BASIC CALL PROCESS: SWITCHING In the switching phase, the CO switch translates the pulses or tones into a port address that connects to the telephone set of the called party. This connection could go directly to the requested telephone set (for local calls) or go through another switch or several switches (for long-distance calls) before it reach its final destination.

Page 14

BLOCK DIAGRAM

Figure 3.13 BASIC CALL PROCESS: RINGING Once the CO switch connects to the called line, the switch sends a 20-Hz 90v signal to this line. This signal rings the phone of the called party. While ringing the phone of the called party, the CO switch sends an audible ring-back tone to the caller. This ring-back lets the caller know that ringing occurs at the called party. The CO switch transmits 440 and 480 tones to the caller phone in order to generate a ring-back. These tones are played for a specific on time and off time. If the called party phone is busy, the CO switch sends a busy signal to the caller. This busy signal consists of 480 and 620Hz tones.

Figure 3.14 BASIC CALL PROCESS: TALKING In the talking phase, the called party hears the phone ringing and decides to answer. As soon as the called party lifts the handset, an off-hook phase starts again, this time on the opposite end of the network. The local loop is closed on the called party side, so current starts to flow to the CO switch. This switch detects current flow and completes the voice connection back to the calling party. Now, voice communication can start between both ends of this connection.

Page 15

BLOCK DIAGRAM

3.6 AUTO DIALING RELAY:In this project, Relay RL2 is a dial relay it, contact are in series with the telephone line. Contacts make break is the principle of dialing, as it was used in olden days with round dial type telephone handsets., if you want to dial 5 just break the contacts 5 times. To dial 0, you will have to break the contact ten times. This type of dialing is known as pulse dialing. By making breaking the contacts we send the series of pulses to exchange, there should be at least one second gap between two numbers. After off-hook operation, auto dialing operation is start. 3.7 MICROCONTROLLER 89C51:-

Figure 3.15 MICROCONTROLLER IC 89C51 IT IS A 8-BIT MICROCONTROLLER WITH 4K BYTE FLASH

Page 16

BLOCK DIAGRAM

Features: compatible with MCS-51TM Products 4K Bytes of in-system Reprogrammable Flash Memory Endurance: 1,000 Write? erase cycle Fully Static Operation: 0Hz to 247 MHz 128 *8 bit Internal Ram 32 Programmable I/O Lines Two 16-Bit Timer/Counters Six Interrupt Sources and programmable serial channel The AT89C51 is a low power; High-performance CMOS 8-bit microcomputer with 4K bytes of flash programmable and erasable read only memory (PEROM). The device is manufactured using Atmels high-density nonvolatile Memory technology and is compatible with the industry-standard MCS-51 instruction set and pin out. The on-chip flash allows the program memory to be reprogrammed in-system or by a conventional nonvolatile memory programmer. By combining a versatile 8-bit CPU with flash on a monolithic chip, the Atmel AT89C51 is a powerful microcomputer which provides a highly flexible and cost-effective solution to many embedded control application. Port 0 is an 8-bit open drain bi-directional I/O Port. As an output port, each pin can sink eight TTL inputs. When 1s are written to port 0 pins, the pins can be used as high impedance inputs. Post during accesses to external program and data memory. In this mode P0 has internal pull-ups. Port 0 also receives the code byte during flash programming and outputs the code bytes during program verification. External pull-ups are required during program verification. All the relays are connected at port 0 through driver circuit. Port 1 is an 8 bit bi-directional I/O port with internal pull-ups. The port 1 output buffers can sink/source four TTL inputs. When 1s are written to port 1 pins they are pulled high by the internal pull-ups and can be used as inputs. As inputs, port 1 pins that are externally being pulled low will source current (IIL) because of the internal pull-ups. Port 1 also receives the low-order address bytes during flash programming and verification.

Page 17

BLOCK DIAGRAM

Port 2 is an 8-bit bi-directional I/O port with internal pullups. The port 2 output buffers can sink/source four TTL inputs. When 1s are written to port 2 pins they are pulled high by the internal pullups and can be used as inputs. As inputs, port 2 pins that are externally being pulled low will source current (IIL) because of the internal pullups. Port 2 emits the high-order address byte during fetches from external program memory and during accesses to external data memory that uses 16-bit addresses (MOVX @ DPTR). In this application, it uses strong internal pull-ups when emitting 1s. During accesses to external data memory that uses 8-bit addresses (MOVX @ R1), port 2 emits the contents of the p2 special function register. Port 2 also receive the high-order address bits and some control signals during flash programming and verification. Port 3 is an 8-bit bi-directional I/O port with internal pullups. The port 3 output buffers can sink/source four TTL inputs. When 1s are written to port 3 pins they are pulled high by the internal pullups and can be used as inputs. As inputs, port 3 pins that are externally being pulled low will source current (IIL) because of the pullups. Port 3 also serves the functions of various special features of the AT89C51 as listed below port P3.0 P3.4 P3.1 P3.2 P3.3 P3.5 P3.6 P3.7 pins RXD T0 TXD INT0 INT1 T1 WR RD Alternate functions (serial input port) (timer 0 external input) (serial output port) (External interrupt 1) (External interrupt 0) (timer 1 external input) (External data memory write strobe) External data memory read strobe)

Table 3.2 PIN DESCRIPTION OF PORT 3 OF MICROCONTROLLER IC 89C51

Page 18

BLOCK DIAGRAM

3.8 SPEECH CIRCUIT IC AP89042:-

Figure 3.16 SPEECH IC AP89042 Ic4 is AP89042 one time programmable speech IC where all the messages has been stored. It is active high triggered IC so initially all the pin logic connected from port 3 is kept low through program, setting any of these pin to high logic, it will trigger the voice stored at the location. AP89042 is a high quality voice synthesizer with a capacity of 32 to 42 seconds. A proprietary ADPCM algorithm is used. The audio message is stored in a 1024-Kbit on chip EPROM. The AP89042 eliminates the need of complicated circuitry in voice playback but Still achieves high voice quality. Sounds such as human speech, animal sounds, musical sounds, and even special sound effects can be synthesized. Devices can be cascaded to achieve longer voice duration. Two devices can be configured in parallel in order to achieve signal mixing without an external mixer allowing speeches to be mixed with background music synthesis from two different chips.

Page 19

BLOCK DIAGRAM

The instant programming nature of the AP89042 allows a very short production turnaround time. There are no NRE charges that are usually required with conventional voice ROMs. Users can now apply a voice synthesis function as an additional feature to their products even when production volume is relatively small. It is also ideal for trial or engineering prototyping. As a result, the initial investment is minimal and the risk in the product development phase is reduced. The AP89042 provides a wide voltage operating range from 3.0V to 6.0V. A pair of PWM output pins. VOUT1 and VOUT2 provide direct drive to a buzzer. Voice quality from a buzzer is comparable to speaker output and power consumption is much lower. A current output pin COUT, enables the device to drive a speaker with a low cost NPN transistor. No complex filtering or amplifier circuit is needed. An automatic ramp up/down function eliminates the undesired noise at the end of playback. The SBT trigger pin can be programmed to playback all 32 sections or sequentially from section 1 to 32. An. Two LED drivers are available, flashing ON and OFF at approximately 3Hz intervals. Following messages had been stored on speech IC that is useful in our project. 1. Please enter your password 2. press 1 for normal ON/OFF 3. Press 2 for password change 4. Press 3 for telephone number change 5. requested channel is ON 6. requested channel is OFF 7. Please enter your new password 8. Your password has been changed 9. Enter new telephone number 10. Your telephone number has been changed 11. Emergency, Emergency, Emergency, please come immediately

Page 20

BLOCK DIAGRAM

3.9 AMPLIFIER CIRCUIT IC LM386:The LM386 is a low power amplifier IC it draws a minimal amount of current and has an output of around 1/2 W. they are often used in low power amplification circuit such as in toys and low cost audio equipment. The gain is internally set to 20 to keep external part count low, but the additional of an external resistor and capacitor between pins 1 and 8 will increase the gain to any value up to 200. The inputs are ground referenced while the output is automatically biased to one half the supply voltages. The quiescent power drain is only 24 mill watts when operating from a 6 volt supply, making the LM386 ideal for battery operating

Figure 3.17 AMPLIFIER CIRCUIT IC LM386 Voice from speech IC is coupled to LM 386 pin no 3 through coupling capacitor and volume control resistor. Audio O/P from pin no 5 of LM386 drives a speakers through capacitor

Figure 3.18 LM386 DRIVES SPEAKER Page 21

BLOCK DIAGRAM

3.10 SERIAL EPROM IC 93C46:-

Figure 3.19 SERIAL EPROM IC 93C46 In 93C46, we can store password and telephone number. Microcontroller compare password with the 93C46. Low voltage and standard-voltage operation User selectable internal organization, word or byte 3-wire serial interface 2 MHz clock rate Self-timed write cycle (10 ms max) High-reliability, 1 million write cycles, 100 year data retention Pin number 1 2 3 4 5 6 7 8 Description CS chip select SK serial data clock D1 serial data input D0 - serial data output GND - ground ORG internal organization NC not connect Vcc positive power supply

Table 3.3 IC 93C46 PIN NUMBER AND DESCRIPTION

Page 22

BLOCK DIAGRAM

3.11 POWER SUPPLY CIRCUIT IC 7805:-

Figure 3.20 VOLTAGE REGULATOR IC 7805 Internal thermal overload protection No external component required Output current in excess of 1A Internal short circuit current limit Available in the aluminum TO-3 package IC 7805 is regulator with heat sink to give 5 v supplies to the circuit. The power input is 9v AC through a step down transformer. Circuit as shown below is give you how 7805 used as power regulator. Check the voltage at the O/P of the regulator; it should be perfectly 5v DC.

Figure 3.21 POWER SUPPLY CIRCUIT 3.12 SENSOR:Sensor is a device which sense parameter like temperature, smoke, fire, pressure etc. in our project we are using five pin sensor connector. In this connector, we are connecting three sensors. Last two pin of this connector is for supply and ground.

Page 23

BLOCK DIAGRAM

3.13 ALGORITHM/FLOWCHART:-

Figure 3.22 FLOWCHART

Page 24

CIRCUIT DIAGRAM

4. CIRCUIT DIAGRAM:-

Figure 4.1 CIRCUIT DIAGRAM OF IVRS SYSTEM

Page 25

CIRCUIT DIAGRAM

4.1 DETAILED CIRCUIT DISCRIPTION:Telephone line is connected connector k1. Ringing signal is around 70v to 75 v is rectified by the bridge rectifier circuit comprising of D5 to D8 and is further filtered and stabilized by c19,r12 and d10 and fed to the ic9 an optocoupler MCT2E through r13. With the ringing signal, led inside the optocoupler will glow and light will fall on the base of the transistor .collector of the transistor is connected to the p3.3 and by default remains high. Whenever light falls on the transistor, the transistor conducts and the collector will become low, six to eight ringing bell will make this transistor to give out six to eight low going pulses. P3.3 will count these pulses and this circuit is called ring detector circuit. Microcontroller will make the pin P1.0 high which was initially kept low with the program. Relay RL1 will become ON resistance R20, R21, and primary of the transformer will come across the telephone line and exchange will understand that telephone handset has been lifted and will disconnect the ringing signal and connect the voice line with the device. Voltage across the telephone line will become 12vdc this circuit is called off-hook circuit. Now since the device has lifted the hand set electronically. The device is supposed to speak now. Ic4 is AP89042 one time programmable speech IC where all the message has been stored. It is active high triggered IC so initially all the pin logic connected from port 3 is kept low by program, setting any of these pin to high logic will trigger the voice stored at that location. First message, the caller will receive please enter your password Caller will enter the password trough his key pad ,the password will reach this circuit in DTMF format and would be connected to DTMF decoder IC 6 through C23,C24,R22,R23,R24,R25and R26. 4bit binary output is available at pin no 11,12,13,14 Q1 to Q4 .Every new byte available on these pins will be indicated by a low going pulse at pin no 15 of this IC which is connected to P1.1 of the microcontroller. Microcontroller will store all the bytes received from its port pins to a temporary location in ram, till it receive the # character. # character IC like end of line character. The microcontroller will read the password stored in the serial EPROM 93C46 and compare the received password, if the password is matching it will proceed further otherwise it will disconnect the telephone line by making P1.0 to low without any reply.

Page 26

CIRCUIT DIAGRAM

OFF-HOOK operation:Before making any call we need to lift up the hand set this process is known as offhook. Before dialing any number microcontroller will make P1.0 pin no 1 to high logic transistor Q1 will become ON, RELAY RL1 will close its contacts and R20,R21 ,C22 & primary of the transformer TR1 will come across the telephone line and the exchange will understand that, hand set is lifted , the device will get the dialing tone. Voltage at K1 should be 12v dc, otherwise check for the above circuit for any dry solder or open circuit. Dialing Operation: Relay RL2 is a dial relay its contacts are in series with the telephone line. Contact make break is the principle of dialing, as it was used in olden days with round dial type telephone handsets. If you want to dial 5 just break the contacts 5 times. To dial 9 break the contact 9 times. Similarly for all the numbers, to dial 0, you will have to break the contact ten times. This type of dialing is known as pulse dialing. By making breaking the contacts we send the series of pulses to exchange, there should be at least one second gap between two numbers. Dial relay is driven by pin P1.6 through R28 and Q2. IC7- 4047 we are using as timer IC, with no communication output of this IC at pin no 10 will be low logic, and will keep the logic at P3.2 pin no 12 of the microcontroller to logic low state during idle state. This pin will only become high during communication period and should become low after 10 second once the communication is over. The timing is decided by the component C20 and R15 resistor. The internal timer starts the movement pin no 8, 12 gets high pulse second pulse must be before 10 seconds. If the pulse do not arrive before 10 second, output at pin no 10 will become low. So the caller must enter the next code through his key pad well before 10 seconds expires. This function is there with the all the telephone exchanges if you do not press the key in time the dial tone gets disconnected. Same features are added here too. This also helps to disconnect the telephone line from the circuit immediately once the communication is over.R16 and C21 gives the required reset pulse to this IC.

Page 27

CIRCUIT DIAGRAM

When bell rings, the collector of the IC 9 will go low, is also connected to pin no 12 and 13 of the IC8 7400 NAND gate IC, output at pin no 11 becomes high is connected to pin no 8 and 12 of IC 7 through D15 resulting pin no 10 of IC 7 will go high .R14 connected to pin number 8 and 12 is to keep the logic to low logic to avoid false triggering. This IC also receives trigger pulse from IC6 through D17 from pin no 15 of IC6 as well as from microcontroller pin P1.7 through D16. All three trigger point will keep the logic at pin no 10 of the IC 7 to high and will become low after 10 second from the last trigger pulse.LD2 LED gives the visual effect of the communication and is driven by the transistors Q3, R18 and R19. Diode D11, D12 AND D18 TO D22 connected across the relay coils are protection diode, they protects the circuits from the induced emf generated by relay coil during on- off operation.D15, D16 & D17 are to avoid reverse biasing and false triggering.Vr1 connected to ic4 is a sample rate adjust variable resistor. Vr2 is a volume control resistor. Voice from IC4 is coupled to IC 5 pin no 3 through C10 coupling capacitor, VR2 and R9. R4 and C11 are tone corrector. Audio output from pin no 5 of the IC 5 drive a speaker through capacitor C15. Output of the speaker points are also connected to the secondary of the matching transformer TR1 so that caller can listen this voice message through telephone line.R10 and C14 are tone corrector. Diode D13 and D14 connected across the transformer in back to back connection is to maintain the impedance same in both the direction. IC7- 4047 acts like watchdog timer, as long communication is going on, it does nothing, the movement communication is over, its output at pin no 10 connected to pin p3.2int0 will interrupt the processor and processor will make the p1.0 low and disconnect telephone line .The time to switch off the off- hook relay is decided by c20 and r15 connected to IC 4047.transister Q3 drives the led LD2 to give visual indication of communication. Transformer TR1 is 1:1 transformer (600:600) provides isolation between telephone line and speech circuit. Port 0 is an output port where relays are connected IC 4 ap89042 is one time programmable, addressable sound IC for complete details refer to its datasheets attached Lm 386 ic4 is a sound amplifier an 8 ohm .5w speaker can be connected for testing purpose, to its output at terminal provided. IC 7805 ic1 is regulator to give 5v supply to the circuit the power input is 12v ac through a steeped down transformer. All relays are 12v type and contact ratings are 7amp at 250volts. Page 28

CIRCUIT DIAGRAM

RELAY CIRCUIT:All the relays are connected to port 0. Port 0 is an open collector port so we have to connect a pull-up resistor network to make all the pins to digital logic high pins. Then through program we make them low, so all the relays are OFF initially. All the relays are operated by 12v dc. Their contact rating is 7 amperes at 220vac. All the transistors Q4 TO Q13 form the relay driver circuit. Each pair of transistor drives one relay operation. Initially since we have connected pullups resistor on PORT 0, Q4, Q6, Q8, Q10 will become ON and Q5, Q7, Q9, Q11 AND Q13 will remain OFF, and all the relays will remain OFF. If I need to switch ON relay RL3, We will make P0.0 to LOW by program CLR bit P0.0. Q4 will become OFF and Q5 will receive High logic at its base through R35 and it will become ON 12v Supply through relay coil will flow through Q5 and ground. Current will flow and normally open contact will close, making contact between pin 1 and 2 of CON2 connector. To switch OFF this relay, Make P0.0 to high by SETB instruction. LD3 TO LD7 is relay ON/OFF indication. All the diodes connected across relay coils are for protection purpose as mentioned earlier

Page 29

CIRCUIT DIAGRAM

4.2 OPERATION:Call the IVRS system telephone number from another telephone number, LD2 will blink. After six to eight rings, you will receive a voice, please enter your password. Dont start entering the password immediately, let the message be over, enter the default password, 123456# you will receive another voice, A menu (if your password entry is correct otherwise the device will disconnected you without giving any reply similar to as we do on wrong number) Press 1 for normal on off Press 2 for password change Press 3 for telephone number change Press star (*) to listen this menu again. You should enter your choice once the message is over. If the password entered is correct. You can also change the password stored or the telephone number change. This data stored goes into serial EPROM IC 93c46 that is non volatile ram, in case power fails, the data is not lost All relays can be switched on as follows 4.2.1 NORMAL ON /OFF MODE:1& 1 to switch on 1st relay 2&1 to switch on 2nd relay 5&1 to switch on fifth relay 9 & 1 to switch on all relays Every time you will receive message requested channel is on Similarly to SWITCH OFF the relays Press channel no and 0 say 1&0 will switch off 1st relay, 2&0 will switch off 2nd relay. 9&0 will switch off all relays You will receive requested channel is off message If you want to know the status of the previously on/ off relays Press channel number and 2, say 2&2 will message whether the channel 2 is on or off.

Page 30

CIRCUIT DIAGRAM

4.2.2 PASSWORD CHANGE:If you want to change the password follow these steps Dial this number from other line after six to eight bells you will receive message please enter your password. (1,2,3,4,5,6 and #)so you enter your password and wait for the message if you enter 2 then device will respond please enter new password. When your password entry is over, press # after password entry indicates that your entry is over and microcontroller will respond your password has been changed Keep the handset back on the instrument from where you are calling. Next time when you dial, you will have to enter your new password. 4.2.3 TELEPHONE NUMBER CHANGE:Dial this number from other line after six to eight bells you will receive message please enter your password. (1,2,3,4,5,6 and #)so you enter your password and wait for the message if you enter 2 then device will respond please enter please enter new telephone number. When your password entry is over, press # after password entry indicates that your entry is over and microcontroller will respond your telephone number has been changed All the sensor should be logic low active whenever any sensor is activated its output will become low and port 2.4, P2.5, P2.6 will detect the pin low. Following action takes place:1. All the loads connected on port 0 will be switched off 2. Emergency message will start. 3. Off hook relay will be activated. 4. Stored telephone number will be dialed out. 5. Emergency message will be delivered. 6. Telephone number will be dialed out five times at the interval of one minute. 7. After five dial out is over sensor will be rechecked if condition still exists again 5 redial will take place. 8. This process will continuous till the condition becomes normal or a person comes and switch off the device.

Page 31

APPLICATION AND FUTURE SCOPE

5. APPLICATION AND FUTURE SCOPE:5.1 APPLICATION:This could be used for verity of purposes where you want to control devices remotely. Suppose you own a partnership company with three or more partners, your business require you to travel frequently, you Have a several in your office and nobody else other then the partners, should operate this server. At the same time you do not want to keep your sever always on. In that case this device comes to your service. Only requirement for this device is parallel telephone connection. And of course power supply. You can switch ON this sever by dialing your office telephone number from anywhere in the world and security telephone number, the number on you will like to receive emergency call from your office in case of any security breach. This is live project in ESSAR STEEL [HBI PLANT], there are four furnace for prepare hot briquetted sponge iron in these furnace. They melt raw material of steel at 1200c. During this process, there is variation in temperature. It is necessary to maintain temperature or to control the temperature. This project help them to when the temperature is goes beyond the limit, this system inform them and call the authorized person automatically and call them till the system become normal. We are also control pressure and smoke by using pressure and smoke sensor. They also on/off the channel using this system and using this system, they also know the status of the channel. 5.2 FUTURE SCOPE:Future of interactive voice response system is very bright. Future of this project depends upon IVRS system. In future, we can use this project as a security level. In this project, we are using off-hook and auto dialing operation. This is required for security code lock system. So we can modify this project and also implement the code lock system with IVRS system. In future, we can drive the boiler according to this project. Presently this project provide safety level, but I future this provide security level. In every industry, safety and security is two basic pillars and this project will provide safety and security. This project will make industrial process more and easier. Page 32

CONCLUSION

6. CONCLUSION:This system provides safety and security which are most useful parameter for the industry. By using this system, we can on/off the devices and also know status of the devices from anywhere. 6.1 ADVANTAGES:1. Cost is less. 2. Provide security. 3. Provide safety. 4. Easy to operate. 5. Small in size. 6. Installation is easy. 6.2 DISADVANTAGES:1. At emergency condition, all the connected devices are OFF, whether it is faulty or not. 2. If we connect sensor with four devices, and short circuit in emergency condition the call is return back to us, but to identify which sensor point is sense the fault in devices at industry side is difficult. 3. After emergency condition, without pressing the reset button, the devices can not on/off normally.

Page 33

APPENDIX

7. APPENDIX: PCB LAYOUT

Figure 7.1 PCB LAYOUT OF IVRS SYSTEM

Page 34

APPENDIX

LIST OF COMPONENTS:COMPONENTS RESISTORS RESISTOR ARRAY VARIABLE RESISTORS RELAYS CAPACITORS DIODES TRANSISTORS ICS CRYSTALS MATCHING TRANSFORMER MAIN TRANSFORMER TELEPHONE CABLE IC SOCKETS SPEAKER RESET SWITCH CONNECTORS HEAT SINK QUANTITY 48 1 2 7 27 22 13 9 2 1 1 1 8 1 1 8 1

Page 35

APPENDIX

BILL OF MATERIALS RESISTOR 1/4W 10E- R10 47E-R20 150E-R4 330E-R21 390E-R18 470E-R13 560E-R11 1K-R1,R3,R9,R36,R39,R42,R45,R48 2K7-R17,R30,R31,R32,R33 4K7-R35,R38,R41,R44,R47 10K-R2,R19,R28,R29,R34,R37,R40,R43,R46 22K-R12 39K-R25 56K-R23 100K-R14,R22,R24,R26 270K-R27 470K-R5,R6,R7,R8 1M-R15 4M7-R16 RESISTOR ARRAY 10K SIP9 TOTAL VARIABLE RESISTOR VR1 MINIPOT -1M VR2 MINIPOT -10K TOTAL RELAYS RL1,RL2 5V RL3 TO RL7-12V DC TOTAL QUANTITY 1 1 1 1 1 1 1 8 5 5 9 1 1 1 4 1 4 1 1 1 49 QUANTITY 1 1 2 QUANTITY 2 5 7 PRICE 1 1 1 1 1 1 1 8 5 5 9 1 1 1 4 1 4 1 1 5 53 PRICE 2 2 4 PRICE 80 100 180

Page 36

APPENDIX

CAPACITORS 33PF - C5,C6 10KPF/275V C23,C24 10KPF DISK C9 100KPF DISK C3,C8,C10,C11,C12,C14,C16,C21,C25,C2 6,C27 100KPF/63V/POLY-C18,C22 4.7MF-C20 10MF-C4,C7,C13 22MF-C19 100MF-C2,C17 220MF-C15 1000MF-C1 TOTAL DIODE 1N4007-D1 TO D4 1N4148-D5,D6,D7,D8,D11,D12,D15,D16 TO D22 3.3V ZENER -D9 5.1V ZENER-D13,D14 15V ZENER- D10 TOTAL TRANSISTORS 547/548- Q1 TO Q13 TOTAL IC 7805 89C51 93C46 AP89042 LM386 8870 4047 7400 MCT2E TOTAL

QUANTITY 2 2 1 11 2 1 3 1 2 1 1 27 QUANTITY 4 14 1 2 1 22 QUANTITY 13 13 QUANTITY 1 1 1 1 1 1 1 1 1 9

PRICE 4 40 2 22 4 2 6 2 4 2 2 90 PRICE 8 28 2 4 2 44 PRICE 39 39 PRICE 10 60 20 250 30 20 30 15 35 470

Page 37

APPENDIX

IC SOCKETS 40PIN 20PIN 18PIN 14PIN 8PIN 6PIN TOTAL OTHER COMPONENT CRYSTAL X1- 11.059MHz CRYSTAL X2- 3.579MHz MATCHING TRANSFORMER TR1600 2 PIN CONNECTORS- CON1 TO CON7 LEDs- LD1 TO LD7 BLANK PCB MAKING PCB LAYOUT MAIN TRANSFORMER- 9V/1Amp TELEPHONE CABLE SPEAKER-8/1W RESET SWITCH 2PIN POWER CONNECTOR HEAT SINK FOR 7805 TOTAL TOTAL AMOUNT

QUANTITY 1 1 1 2 2 1 8 QUANTITY 1 1 1 7 7 1 1 1 1 1 1 1 1 25 -

PRICE 20 15 15 15 10 10 85 PRICE 30 30 80 35 5 110 300 35 40 25 5 20 10 725 1690

Table 7.1 BILL OF MATERIALS

Page 38

APPENDIX

WORK PHOTOGRAPHS

Page 39

APPENDIX

Page 40

APPENDIX

REFRENCES:WEBSITES:-

http://www.wikipedia.org http://www.howstuffworks.com/ http://www.kpsec.freeuk.com/ http://www.electronicrepairguide.com/ http://www.siongboon.com/ http://www.futurlec.com/

BOOKS: THE 8051 MICROCONTROLLER AND EMBEDDED SYSTEMMUHAMMAD ALI MAZIDI, JANICE GILLISPIE MAZIDI, ROLIN D, MCKINLAY

Page 41