GAS LEAKAGE ALERT WITH POWER FAILURE SYSTEM AND AUTO DIAL

TABLE OF CONTENTS

INTRODUCTION SYNOPSIS BLOCK DIAGRAM BLOCK DESCRIPTION CIRCUIT DIAGRAM CIRCUIT DESCRIPTION WORKING PRINCIPLE FABRICATION OF CIRCUITS SUGGESTIONS FOR IMPROVEMENTS APPLICATIONS CONCLUSION BIBLIOGRAPHY

INTRODUCTION

INTRODUCTION
The advent of modern digital technology and the surface mount technology, latest communication technologies and the far reaching technologies related to instrumentation and remote sensing and all such developments are contributing to the benefit of the human race so as to make him live is peace harmony life easy, safe and comfortable. Everyday new technologies are coming in so that it is hardly possible to predict as to how and what would be technology of tomorrow. Incoming new technologies are really, directly and indirectly, creating benefits & challenges as well to mankind. Of course LPG gas is a benefit man enjoys as an outcome of science and technology. The comfort of the gas comes along with the threats of its own hazards as well because of a possible gas or petrol leakage. News of dangers of burnings and explosions of gas cylinders due to gas leakage are also coming in, if not everyday at least now and then. Yes. We witness both benefits and challenges out of science and technology. It is obligatory on every human being to face the challenges and threats, just without giving any way for frustrations that may slowly lead into many difficulties, if not faced with courage. From time immemorial the war between the advantages of science which evolve by human error and machine failure is on. We in this project have attempted to support the theory of being on the right side to positively and boldly face the menaces of gas leakage hazard using the latest technologies.

SYNOPSIS

SYNOPSIS
Accidents due to fuel leakage are dangers encountered several times. We have, therefore, in his project, attempted to develop a system that features the sensing of gas leakage and giving an alarm. The ultra modern micro electronics has made opportunities for the development of such security system with the advent of advanced sensors for sensing touch and fuel leakage. It is because of the developments in the field of transducers that leads the way for such projects. Fuel leakage sensing is developed using a special transducer that uses highly activated carbon granules. In the vicinity of the activated carbon enclosure is a heater. There are two electrodes separated by an air gap. If the flammable fuel particles mixed in air reaches the air gap of the fuel leak sensor the current between the two electrodes increase and the increase in current is monitored and used to generate the alarm. Once a gas leakage is monitored the gadget immediately gives signal to the alarm device The alarm device is a buzzer that gives a low sounding alarm.

BLOCK DIAGRAM

BLOCK DIAGRAM

BLOCK DESCRIPTION

BLOCK DESCRIPTION
The main blocks of the project are, 1. The fuel leakage sensor. ( Activated carbon leak detector) 2. The alarm device. ( A hooter )

3. The Power supply system.

4,1 The LPG Gas Leakage Sensor. ( Activated carbon leak detector) The fuel leakage detector system is to smell out the presence of any dissolved gas particles in the environmental air inside the car. If the density of gas particles dissolved in the air inside the car is more than a threshold level the alarm is activated. The presence of LPG particles in air is monitored in terms of parts per million. If the parts per million of the LPG elements in air exceeds the set level the electronic system gives the alarm. The sensor used for this purpose is of the activated carbon type. It is a passive transducer. An applied voltage across the two plates of the sensor

causes a nominal current through the circuit and if the density of LPG is high in the air then the conduction of the sensor increases and the increased current is responsible to activate the alarm circuit. The activated carbon sensor is specially designed by its manufacturer to detect Petroleum related leakages into air.

4,2 The Alarm Device. ( A hooter ) At the event of a gas leakage then a local alarm is activated.. To achieve this sensor gives logic information to the relay activating circuit and the relay then closes the buzzer unit. The buzzer is the source of alarm inside the car and the sound is normally sufficient to draw the attention of the people.

CIRCUIT DIAGRAM

CIRCUIT DIAGRAM

CIRCUIT DESCRIPTION

CIRCUIT DESCRIPTION
6,1Overall Circuit Operation The project has been designed to serve the objective of sensing and raising an alarm in the event of a gas leakage. It is supposed to be reliably useful to make a definite alarm in the event of a gas leakage. The alarm is supposed to ring at the surroundings of the leakage area say a house or a hotel or a factory premises. As such the factor to be monitored is leakage of LPG gas. To detect any gas leakage we have to install a gas leakage detector. he gas leakage is detected using an advanced transducer called the Activated Carbon LPG detector. This is a passive transducer and a voltage is normally impressed actross its terminals and the current through an external resistor is monitored. If the current through the external resistor is enhanced severely then it means the sensor is in the presence of air with LPG particles dispelled in it. Thus a measure of the current through the external resistor made in terms of the voltage drop across the resistor is an indirect measure of the gas leakage dispelled in air. This voltage is compared in a comparator, against a set point voltage and if the voltage is more than a threshold value then a logic high level voltage of 5 volts is produced by the comparator.

This logic high level voltage is responsible for turning On the alarm both at the local larm device and at the remote alarm device 6,2 The LPG Sensor The Gas leak is detected by the gas leakage detector. The gas leakage detector is a high technology device that uses the principle of thermionic emission between two plates held at different electrical potentials. The amount of current flow between the two electrodes is a function of the voltage between the two electrodes, the temperature of one of the two electrodes the cathode and the amount of mixture of any inflammable gas particles in terms of parts per million in the air between the two electrodes. With reference to the sensor that we use, it consists of a ring of activated carbon. Inside the ring of carbon particles are two electrodes held apart. There is a heater inside the unit to heat up the cathode. Electrical connections are brought out from the Plate or Anode, the Cathode and the heater An external source of DC potential of say 5 volts is applied to the heater. The Anode is held at a potential of about 24 volts with respect to the cathode. The external circuit is completed through a fixed a and a variable resistor. The voltage drop across the fixed resistor is a measure of conduction between the anode and cathode of the sensor and therefore the amount of this voltage drop is used for monitoring the degree of gas leakage.

The two electrodes are enclosed inside a ring of activated hydro carbon. The property of the hydro carbon is to attract the air particles that are rich in mixed LPG particles. Thus the concentration of LPG mixture in air is more inside the carbon ring. Leakages of LPG in the room causes the carbon ring to attract the LPG mixed air particles and make a concentration of LPG mixed air inside the ring so as to improve the electrical conduction between the plates of the Sensor. While in normal operation the anode is held at a DC potential of 24 volts. The heater is applied with 5 volts. The hot cathode now emits electrons just like a thermionic valve these electrons are attracted by the positive anode and thus a current is caused to flow between the cathode and the anode. This is the cause of the external current as well. The external current flows through external fixed resistor and a variable resistor. In the absence of mixture of LPG in air this current is very small and makes a very small drop across the external fixed resistor. But with increased LPG mixture richness in air the conduction increases and the current through the external resistor is also very high and the voltage across the external resistor is also very high. The drop across the external resistor is a function of the LPG richness in air and the relation between the output voltages with respect to the richness of LPG in air is almost linear. The variable resistor that comes in series with the fixed resistor is to adjust the level of detection or sensitivity of LPG leakage detection. This is

essential because in some areas like kitchens etc., the air is normally dispelled with LPG particles because off the burning of LPG, however this is not a leakage. Therefore a sensitivity control is essential to set the threshold of sensing and alarming. 6,3 The Operational Amplifier Comparator Operational amplifiers are high gain amplifiers in the form of integrated circuits. They have a number of advantages over conventional amplifiers that make them suitable for many industrial applications. The various modes of operation of the operational amplifiers are, 1. Inverting amplifier. 2. Non Inverting amplifier 3. Comparator. 4. Adder. 5. Subtractor. 6. Sign Changer. 7. Scale Changer. 8. Astable Multivibrator. 9. Mono stable Multivibrator and so on..

In our project we have used the operational amplifier in the comparator mode. The operational amplifier IC 741 has 8 pins and of the 8 pins, 2 are used for power supply and two are used for input and one pin is used for getting the output.

In the comparator mode, the operational amplifier is fed with two inputs and the two inputs are the inverting inputs and the non inverting inputs. While in the comparator mode of operation, if the potential at the non inverting input is higher than that at the inverting input then the output will be the same as the positive operating voltage. Similarly if the potential at the inverting input is higher than that at the non inverting input then the output will be the same as the negative operating voltage. In our project we have used the comparator with two input signals one from the gas leakage sensor and the other from the sensitivity control unit. The sensitivity control voltage is is applied to inverting input and the Gas Leakage Sensor voltage is applied at the non inverting input. At normal condition the voltage at the sensitivity control input is more than that at the other input therefore the output of the operational amplifier is a high negative potential compared to the maximum operating positive voltage. This voltage is not sufficient to drive the transistor at the output of the operational amplifier. Whenever there is a gas leakage the Gas Leakage Sensor output is more than that at the sensitivity control input of the operational amplifier. This causes the output of the operational amplifier to go high and it drives the transistor at the output of the operational amplifier and the output of this transistor goes high. This transistor drives the tone generating astable multivibrator. The output of the Astable multivibrator is connected to the transistor ads the modulating signal.

WORKING PRINCIPLE

WORKING PRINCIPLE

The project has been designed to serve the objective of sensing and raising an alarm in the event of a gas leakage. It is supposed to be reliably useful to make a definite alarm in the event of a gas leakage. The alarm is supposed to ring at the surroundings of the leakage area say a house or a hotel or a factory premises. As such the factor to be monitored is leakage of LPG gas. To detect any gas leakage we have to install a gas leakage detector. The gas leakage is detected using an advanced transducer called the Activated Carbon LPG detector. This is a passive transducer and a voltage is normally impressed across its terminals and the current through an external resistor is monitored. If the current through the external resistor is enhanced severely then it means the sensor is in the presence of air with LPG particles dispelled in it. Thus the measure of the current through the external resistor made in terms of the voltage drop across the resistor is an indirect measure of the gas leakage dispelled in air. This voltage is compared in a comparator, against a set point voltage and if the voltage is more than a threshold value then a logic high level voltage of 5volts is produced by the comparator. This logic high level voltage is responsible foturning on the alarm both at the local alarm device and at the remote alarm device.

FABRICATION OF CIRCUITS

FABRICATION OF CIRCUITS
MICRO CONTROLLER UNIT 8,1 FLASH EPROM Flash EPROM is electrically erasable, like EEPROM, but most Flash devices erase all at once, or in a few large blocks, rather than byte-by byte like EEPROM. Some flash EPROMs require special programming voltages. As with EPROMs, the number of erase/program cycle is limited. 8,2 CPU The cpu, or central processing unit, executes program instructions.

Types of instructions include arithmetic (addition, subtraction), logic (AND, OR NOT), data transfer(move), and program branching(jump) operations. An external crystal provides a timing reference for clocking the CPU. 8,3 RAM RAM (random-access memory) is Where programs store information for temporary use. Unlike ROM, the CPU can write to RAM as well as read it, Any information stored in RAM is lost when power is removed from the chip. The PIC has 128 X 8 bytes of RAM. BASIC-52 uses much of this for its own

operations, with a few bytes available to users. 8,4 I/O PORTS 1/0 (Input/output) ports enable the PIC to read and write to external

memory and other components. The PIC has four 8-bit I /O ports (ports 0-3).

As the name suggests, the ports can act as inputs (to be read) or outputs (to be written to). Many of the port bits have optional, alternate functions relating to accessing external memory, using the on-chip timer /counters, detecting external interrupts, and handling serial communications. BASIC-52 assigns alternate functions to the remaining port bits. Some of these functions are required by BASIC-52 while others are optional. If you dont use an alternate function, you can use the bit for any control, monitoring, or other purpose in your application. 8,5 TIMERS AND COUNTERS The PIC has three 16-bit timer/counters, which it easy to generate periodic signals or count signal transitions. BASIC-52 assigns optional functins for each of the timer/counters. Timer 0 controls a real-time clock that increments every 5 milliseconds. You can use this clock to time events that occur at regular intervals, or as the base for clock or calendar functions. Timer 1 has several uses in BASIC-52, including (PWM) (a series of pulses of programmable width and number); writing to a line printer or other serial peripheral (LPT); and generating pulses for EPROM programming (PGM PULSE). Timer 2 generates a baud rate for serial communications at SER IN and SER OUT. These are all typical applications for timer / counters in microcontroller circuits.

8,5 SERIAL PORT The PIC serial port automatically takes care of many of the details of serial communications. On the transmit side, the serial port translates bytes to be sent into serial data, including adding start and stop bits and writing the data in a timed sequence to SER OUT. On the receive side, the serial port accepts serial data at SER IN and sets a flag to indicate that a byte has been received. computer. 8,6 EXTERNAL INTERRUPTS INTO and INT1 are external interrupt inputs, which detect logic levels or transitions that interrupt the CPU and cause it to branch to a predefined program location. BASIC-52 uses INTO for its optional direct-memory-access (DMA) function. 8,7 ADDITIONAL CONTROL INPUTS Two additional control inputs need to be mentioned. A logic high on RESET resets the chip and causes it to begin executing the program that begins at 0 in code memory. In the PIC BASIC chip, this program is the BASIC-52 BASIC-52 uses the serial port for communicating with a host

interpreter. EA (external memory access) determines whether the chip will access internal or external code memory in the area from 0 to 1FFFh. In BASIC52 systems, EA is tied high so that the chip runs the BASIC interpreter in internal ROM on boot-up.

8,8 POWER SUPPLY CONNECTIONS And, finally, the chip has two pins for connecting to a+5-volt power supply (VCC) and ground (VSS). That finishes our tour of the PIC BASIC chip.

Were now ready to put together a working system. To+5V. or use a jumper as show in the schematic, to allow you to bypass BASIC-52 and boot to an assembly-language program in external memory, 8,9 CRYSTAL XTALI is an 6 MHz crystal that connects to pins 18 and 19 of U2. this crystal frequency has two advantages. It gives accurate baud rates for serial communications, due to the way that the PIC timer divides the system clock to generate the baud rates. Plus, BASIC-52 assumes this frequency when it times the real-time clock, EPROM programming pulses, and serial printer port. 8,10 CORE FEATURES High Performance RISC CPU Only 35 single word instructions to learn All single cycle instructions except for program branches which are two cycle Operating speed : DC 20 MHz Clock Input DC 200 ns Instruction cycle 2K*14 words of FLASH Program Memory 128* 8 bytes of Data Memory (RAM) 64*8 bytes of EEPROM Data Memory Pinout compatible to the PIC 16CXXX 28 and 40 pin devices

 Interrupt capability (upto 11 sources) Eight level deep hardware stack Direct, Indirect and relative addressing modes Power-on Reset Power-up timer and Oscillator Start-up timer Watchdog Timer with its own on-chip RC Oscillator for reliable operation Programmable code-protection Power saving SLEEP Mode Selectable Oscillator options Low-power, high-speed CMOS FLASH/EEPROM technology Fully static design In-circuit Serial Programming via two pins Single 5V In-circuit Serial Programming capability In-circuit debugging via two pins Processor read/write access to program memory Wide Operating voltage range : 2.0 to 5.5V High Sink/Source Current : 25mA Commercial and Industrial temperature ranges Low-power consumption - Less than 1.6mA typical @ 5V, 4MHz - 20 micro Amps typical @ 3V, 32 KHz - Less than 1 Micro Ampere typical standby current

8,11 PERIPHERAL FEATURES Timer 0 : 8 bit timer /counter with 8-bit prescaler Timer 1 : 16 bit timer / counter with prescaler, can be incremented during sleep via external crystal / clock Timer 2 : 8 bit timer / counter with 8-bit period register, prescaler and post-scaler 10 bit multi-channel Analog to Digital converter Universal Synchronous / Asynchronous Receiver, Transmitter with 9 bit address detection Parallel slave port 8-bits wide, with external read, write and control signals Brown-out Detection circuitry for Brown-out reset One Capture, Compare, PWM Module - Capture is 16 bit max, resolution is 12.5 ns - Compare is 16 bit max, resolution is 200ns - PWM max resolution is 10-bit

8.12 PIC 16F877

8,13 PIN DIAGRAM PIC 16F877 PIC 16F877 is available in 40 pin DIP Package. It has five ports PORT A - IPORT B - 8 Bits PORT C - 8 Bits PORT D - 8 Bits PORT E - 3 Bits 8.14 LCD DISPLAY MODUL Using an LCD display, the micro controller displays the required information. The Liquid Controlled Display is a ready-to-use module based on the regular IC SED1278 manufactured and marketed by SEIKO EPSON Corporation, Japan. The module has 14 pins as input. The pin 1 is supply ground. The pin 2 is supply +ve of 5 V DC. The pin 3 is used to vary the contrast of the display. Generally a 10K preset connected across the supply and the center wiper connected to the pin is the suggested arrangement to vary the contrast. To make the design simple, the contrast pin is tied to ground for maximum contrast. Pin 4 is for informing the module, whether the byte given to the module is command word or ASCII character. This pin is designated as RS Register select. By making this low, the data supplied is directed command register. The same way, when this pin is high, the data supplied is directed to its internal display RAM. The pin

5 is used for writing or reading the registers of the LCD module. But in this project, this pin is tied to ground. This means the LCD can only be written into but not read from. The reading of LCD registers is done only to see if the busy flag is set, so that next data can be sent. This problem is overcome by giving sufficient gap between data writes to LCD. Pin 6 of the LCD is used to enable the LCD operation and this pin is pulsed to transfer the DATA into LCD. Pin 7 to pin 14 are used to send D0 to D7 or 8-bits of data. The design of this module permits the module to be driven by a 4-bit data words. To send 8-bits of data, first the higher 4-bits are to be sent and then the next lower bits are sent to the module. Pin 7 to pin 10 are not used in this 4-bit configuration. Pin 11 gets D0 and pin 12 gets D1, pin3 D2 and pin 14 to D4. In this method, only 6-bits are required to control LCD display and one of the output port is designated as LCD port and that port drives the LCD module. This is the sequence of commands to initialization of LCD module in the project.

8,15 RELAY DRIVER (ULN 2003A)

Driver IC ULM 2003

IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 GND ULM 2003

Out1 Out2 Out3 Out4 Out5 Out6 Out7 Vcc

The ULN2003A is a high voltage, high current, Darlington Arrays each containing seven open collection Darlington pairs with common emitters. Each channel rated at 500mA and can withstand peak currents of 600mA. Suppression diodes are included for inductive load driving and the inputs are pinned opposite to outputs to simplify layout. It is a 5V TTL, CMOS. This versatile device is useful for driving a wide range of loads including solenoids, relays, DC motors, LED displays And high power buffers. Outputs can be paralleled for higher current. The output of MC is applied to the input of relay driver transistor at its phase terminals. When the input base voltage is reduced so that the relay is deenergized, the collector current falls to zero abruptly. This sudden switching off the relay current induces a very high back emf in the relay coils, which may be high enough to puncture the collector-emitter junction at the transistor and damage it. A large capacitor connected in parallel with the relay coil absorbs this transient and protects the transistor. However large capacitor connected in parallel with the relay coil absorbs this transient, protects the transistor and sluggish the relay operations. In an alternative method, a diode is connected in parallel with relay coil instead of the capacitor. During normal operation, the diode is reversed biased and has no effects on circuit performance, but, when the high back emf is induced, it has the proper polarity for the diode to conduct. The diode there after conducts heavily and absorbs all the transient voltage. The use of a diode is parallel with the relay coil is highly recommended.

8,16 RELAY Reas are switching devices. Switching devices are the heart of industrial electronic systems. When a relay is energized or activated, contacts are made or broken. They are used to control ac or dc power. They are used to control the sequence of events in the operation of a system such as an electronic heater, counter, welding circuits, and X-ray equipment, measuring systems, alarm systems and telephony.

Electromagnetic relays are forms of electromagnets in which the coil current produces a magnetic effect. It pulls or pushes flat soft iron armatures or strips carrying relay contacts. Several relay contact can be operated to get several possible ON/OFF combinations. 8,17 OPERATION OF ELECTROMAGNETIC RELAY : Relays are usually dc operated. When dc is passed to the coil, the core gets magnetized. The iron armature towards the core contacts 1 and 2 open and contacts 2 and 3 close. When coil current is stopped, the attraction is not there and hence the spring tension brings 1 and 2 to closed position, opening the other set 2 and 3.

8.18 ELECTROMAGNETIC RELAY

8,19 RELAY CONTACTS AND IDENTIFICATION :

The heart of the relay is the junction of the contact points. The relay contact points may be flat, spherical, pointed and combination of all these. Flat contacts require more pressure for perfect contact closing. Half round contacts are better because the surface

contamination will be minimum. The twin contacts give reliable operation. Relay contacts are made of silver and silver alloys in small power applications. For large relays, contacts are made up of copper. Certain relays use silver palladium of platinum ruthenium alloys for contacts. The special types mentioned above give long life, carry moderate currents and keep shape for long time.

To identify relay contacts, some important contact arrangements must be remembered.

SPST SPDT NO NC Break

- Single Pole Single Throw - Single Pole Double Throw - Normally Opened - Normally Closed - Relay action opens or breaks contacts

Make

- Relay action makes or closes contacts

Relays are electromagnetic device by which operation of one or more circuits can be controlled by the operation of some other circuit. Relay is a type of switch where switching completely depends upon the electromagnetism. When winding of insulted wire is made on soft iron rod and apply is given across its end then magnetic field develops around the rod and due to this magnetic field, magnetism also becomes magnet. In this way, can be said that on giving supply to the coil winded over a core, it becomes magnet. This magnet is known as electromagnet. Relay is a device which can turn ON/OFF any external circuit in some special circumstances. The principal relay is a one pole 2 way

switch. The difference is that simple switch is manual switch where as relay is an automatic switch to some extent. It has a coil in it. When this coil gets enough supply then it becomes electromagnet and attracts the strip of pole towards itself and changes the position of switch. When supply cuts off then coil demagnetizes and thus switch comes in its normal position. In telephony, the relays are used widely. The relay that we used in this circuit has two states. 1. Normally closed state (NC) 2. Normally opened state (NO) The control circuit of the relay transistor is shown in figure. When the input to transistor is logic 0, the transistor will be open. So the relay will be holding +12 and which will be in normally closed state. Relays are electro mechanical switches and are electrically operated power switches. A relay consists of an electromagnet which when energized pulls the armature. The armature carries heavy electrical contacts that make or break an electric circuit. General purpose relays can handle current of five or ten amperes. Relays that have contact ratings of about 25A or more are known as contactors. A single relay can make or break a number of contacts simultaneously. The amount of electrical power required to drive a relay is very small. Most Voltage stabilizers use relay coils of 720mw.It means that 12v relay coil will have resistance of 200 ohms and operated up to 60mA.The same relay with

450 ohms coil will operate on 18v with 40mA.Transistor circuits can easily supply this much of power and this much of power and thus control large amount of power through relay contacts. When the relay is not activated (ie.) in the reenergized state, Nc contacts are closed and NO connections are opened. When the relay is activated (ie.)in the energized state, NC contacts broken and NO contacts are made. When the relay is de energized the original states of the contacts are returned. The Above relays are single contact relays. This means that the relays have one common point, one NO contact and one NC contact. Double contact relays are also present. These relays have a set of common points, a set of NO contacts and set of NC contacts. In single contact relay, only one relay independent load or a series of different loads can be connected. In double contact relay, two independent loads can be connected at two different contacts and these two different and these two loads can be operated as desired.

8,20 LM78XX Series Voltage Regulators General Description The LM78XX series of three terminal regulators is available

with several fixed output voltages making them useful in a wide range of applications. One of these is local on card regulation, eliminating the distribution problems associated with single point regulation. The voltages available allow these regulators to be used in logic systems, instrumenta-tion, HiFi, and other solid state electronic equipment. Al-though designed primarily as fixed voltage regulators these devices can be used with external components to obtain ad-justable voltages and currents. The LM78XX series is available in an aluminum TO-3 pack-age which will allow over 1.0A load current if adequate heat sinking is provided. Current limiting is included to limit the peak output current to a safe value. Safe area protection for the output transistor is provided to limit internal power dissi-pation. If internal power dissipation becomes too high for the heat sinking provided, the thermal shutdown circuit takes over preventing the IC from overheating. Considerable effort was expanded to make the LM78XX se-ries of regulators easy to use and minimize the number of

external components. It is not necessary to bypass the output, although this does improve transient response. Input by-passing is needed only if the regulator is located far from the filter capacitor of the power supply. For output voltage other than 5V, 12V and 15V the LM117 series provides an output voltage range from 1.2V to 57V. Features n Output current in excess of 1A n Internal thermal overload protection n No external components required n Output transistor safe area protection n Internal short circuit current limit n Available in the aluminum TO-3 package 8,21 Voltage Range LM7805C 5V LM7812C 12V LM7815C 15V

8,22 PCB DESGNING AND FABRICATION PROCEDURE FOR MAKING THE PCB 1. PREPARING OF LAYOUT With the diagram and all the components at hand, draw a complete layout plan of the circuit on a sheet of a tracing paper. As a model, for laying the circuit, a thermo Cole base may be used to hold components. Avoid over crowding of components while making full space utilization. Keep the ground line on the side of the PCB and the supply line on other side as far as possible. When all the components have been mounted on the tracing paper sheet fixed on a piece of thermo Cole base, take out a Sketch Pen for making in such a way that all the connecting wires are equal in width, termination rounded off. Re-draw it on a fresh paper if required.

2. PAINTING OF PCB The tracing so prepared has to be imposed over the copper printed circuit board keeping in view that the component would be mounted from the non-clad side of the board. Take a PCB lamination sheet and cur a piece of required size of the board by

using hacksaw file edges, put the copper clad sheet on the table keeping side on the runway the dirt grease and oxide with a sand paper with its marked side tracing the carbon paper and at her side on top. Since the tracing paper is transformed you can now reproduce a carbon point over a surface but using ball

pen on a hard pencil over the drawing on the transparent side. When the carbon print has been obtained over the copper clad board drill ropes in the board using a hand drill. The holes may be draw with 1/32 bit for

componentleadsandthecarbonshouldberaisedorwipedbymistake.Painttheconnecti ng lines with the help of an ordinary paint. Edges should be scratched with tip of razor blade.

3. DEVELOPMENT OF THE PRINTED CIRCUIT DIAGRAM After painting the board, it will be made by the cool air for sometime. Now take a plastic tray and get some Fe Cl3 chemical powder. The ferric chloride salt is then added with 500ml of water. The color of the solution is pink. Color of the salt is in

yellow. Now we add three to five drops of dilute HCL or H2S04. This is necessary to quicken the process.

4.ETCHING OF PCB Now we take the painted copper clad board and dip it in the solution kept in the tray. After 15 to 25 minutes we see the board, with only printed pattern portion remaining in other places the copper coating is removed due to the chemical action. Then

the board is taken out and washes in water. After wash the board by using thinner solution. Now a printed circuit has been formed on the board.

Take fresh water and mix a few teaspoons of Fe CL3 add a few drops of dilute HCL to it, as it speeds the etching process. Shake well immerse the PC Bin the solution for about 20 minutes occasionally altering the solution by giving the seesaw reaction to the disk storing reduces the etching time. Observe the changing color on the copper surface. Take out the PCB only when the un portion of the copper painted surface

is completely dissolved in the solution wash the PCB with the water. After the PCB is thoroughly washed remove the paint by soft pieces of the cloth dipped in thinner or turpenti 5. DRILLING OF HOLES Then take a drilling machine with 1/32 drill bit to make holes for the incretion of the components use 1/18 drill bit for inset wires and other thick components. Now the PCB is ready to use. ADVANTAGES: 1. Reliability in operation and low cost. 2. Space required becomes less. DISADVANTAGES: It cant withstand larger weight such as transformer. 6.MATERIAL REQUIRED

1. Copper clad sheet [It is made of hylam or nylon board over which the sheet copper is pressed.] 2. Paint or Nail polish or even PCB Ink. 3. Painting brush, tray. 4. Ferric chloride solution and also few drop of dilute HCL or H2SO4. 5. Thinner or kerosene or p 6. Cotton cloth.

7. Trace paper. 8,23SOLDERING Solder is an alloy of tin and lead used for using metals relatively low temperature about 260-315k the point where two metal conductors are to be fused is heated and then solder is applied so that it can melt and cover the connection. The reason for soldering connection is that it makes a good blend between the joined metals.

Covering the joint completely is to prevent oxidation. The coating of solder provides protection for practically an in definitive period of time. The trick in soldering is to heat the joint, not the solder. When the join is not enough to melt the solder the cracks, forming a shifty cover without until the solder has set, which takes only a few seconds. Either a soldering gun can

be

used,

rated

at

25-

10,000. The gun is convenient for the intermittent operation, since it heats almost instantaneously when for press the trigger. The small pencilironof254,000ishelpfulor small connections where excessive heat cause damage. This precaution is particularly important when working on PCB boards, where too much heat can soften the plastic form and loosen the printed writing, a soldering iron for F&T devices should have the tip ground to eliminate static charge. The three grades of solder, generally used for electronics workare40-60, 50-50, and 60-40 solder. The 60-40 solders costs more but it melts at the lowest temperature flows more freely takes less time to harder, and generally makes it easier to do a soldering job. In addition to the solder there must be flux to move any oxide film on the metals being joined otherwise they cannot fuse. The flux enables the molten solder to wet the metals so that the solder can stick. The two types are acid flux and rosin flux. Acid flux is more active in cleaning metals but is corrosive. Rosin flux is always used for the light soldering work in making wire connection. 8,24 POWER SUPPLY

Most electronic circuits require DC voltage sources or power supplies. If the electronic device is to be portable, then one or more batteries are usually needed to provide the DC voltage required by electronic circuits. But batteries have a limited life span and cannot be

recharged. The solution is to convert the alternating current lose hold line voltage to a DC voltage source. 8,25BLOCK DIAGRAM FOR POWER SUPPLY:

TRANSFORMER

RECTIFIER

FILTER

REGULATOR

Block diagram of AC to DC power Supply consists,

1. Transformer: Steps the household line voltage up or down as required. 2. Rectifier 3. Filter : converts ac voltage into dc voltage : smooth the pulsating DC voltage to a varying dc voltage 4. Regulator : fixed the output voltage to constant value.

8,26 Transformer:

The basic transformer consists of a primary winding of N1 turns and secondary winding of N2 turns. When an alternating line voltage V1, is applied to the primary winding, an alternating current it creates a flux. The flux flows through the magnetic core, includes an alternating current I2, which in turn generates an alternating voltage V2 in the secondary winding. Three important specifications are the secondary winding, power rating and the regulation factor.

MAGNETIC CORE FLUX

I1

I2

V1 8,27Rectifiers:

V2

A rectifier circuit converts an AC voltage into a pulsating DC voltage. This is accomplished by using one or more diodes because diodes conduct current in only one direction.

8,28 Types Of Rectifiers: Half-wave Rectifier

Full-wave Rectifier Full-wave bridge rectifier

Half-wave Rectifier:

The transformer (T1) isolates the household voltage and also steps down the household voltage to a more useful voltage level. The diode lets current flow into the load in only one direction. The load current is unidirectional; therefore, it has a significant dc component (or average value).When V2 is positive, diode D1 conducts and VL=V2. When V2 is negative, diode D1 blocks the current flow and VL=0volts. The load voltage consists of dc voltage along with ripple voltage. In a half-wave rectifier circuit, the ripple component is lager than the DC component, which is undesirable.

D1 V1 T1 V2
DIODE

VL

LOAD

USEFUL FORMULAS: VAVG (DC) = 0.637V2 VL (DC) VL (AC) = 0.318V2 = 0.386V2

%RIPPLE = VL (AC)/VL (DC) = 121% RIPPLE FREQUENCY = SUPPLY FREQUENCY 8,29 Full-wave Rectifier :

The full wave rectifier circuit requires a transformer with two secondary windings. I.e. a center-tapped secondary winding. The secondary windings are 180 out of phase.

VL D1 V2a V1 V2b D2 IL LOAD

Diode D1 contacts when V2a is positive, producing a half-wave rectified voltage across the load. Diode D1 does not conduct when V2a is negative. Diode D2 contacts when V2b is positive and does not conduct when V2b is negative. One of the two diodes is conducting at all times because V2a and V2b are 180 out of phase and thus producing full-wave rectified voltage. In the Full wave rectifier, Dc component is larger than ripple.

6,30 USEFUL FORMULAS: VL (DC) VL (AC) = 0.637V2 = 0.3072

%RIPPLE = VL (AC)/VL (DC) = 48.2% RIPPLE FREQUENCY = 2 x SUPPLY FREQUENCY 8,31 Full-wave bridge rectifier:

The full-wave bridge rectifier circuit requires four diodes. The transformer has only one secondary winding.

IL T1 V1 D1 V2 D4 D3 D2 VL LOAD

When V2 is positive, diodes D1 & D3 conduct current through the load. Diodes D2 and D4 block current flow. When V2 is negative, diodes D2 and D4 conduct current through the load. Diodes D1 and D3 block current flow. The full-wave bridge rectifier fully utilizes the transformer winding during both half cycles. 8,32 USEFUL FORMULAS: VL (DC) VL (AC) = 0.637V2 = 0.307V2

%RIPPLE = VL (AC)/VL (DC) = 48.2% RIPPLE FREQUENCY = 2 x SUPPLY FREQUENC

8,33 Filters: The 121% ripple in the output of the half-wave rectifier and 48% in the full-wave rectifier is more than can be normally tolerated. In the full wave filtering, wherein the frequency of the ripple is 100Hz for a 50Hz ac line voltage. This is an advantage where either an inductor is used to prevent the passage of the ripple current(due to its high inductive reactance to ac but quite low resistance to dc), or a capacitor is used to short the ripple to ground but leave the dc to appear at the output. Various combinations of L and C are also used.

8,34 Regulators The simplest regulator is a large capacitor in parallel with the load. The capacitor stores DC voltage while the load voltage increases to its peak value. The capacitor converts the pulsating DC voltage of a rectifier into a smooth Dc load voltage. Two important parameters of a capacitor regulator are its working voltage and its capacitance. The working voltage must be at least equal to no-load output voltage of power supply. The capacitance determines the amount of ripple that appears on the Dc output when current is drawn from the circuit. The amount of ripple decreases with increase in capacitance.

8,35 Capacitance regulator circuit : L-regulator circuit :

This circuit consists of a series inductor and a capacitance in parallel with load. The L-regulator is often used in high-power DC supplies.

MC 7800 and 7900 Regulators standard application circuit: The Mc 7800 is a 3 terminal, positive, fixed voltage integrated circuit regulator. These regulators employ internal current limiting, thermal shutdown and safe area compensation. The Mc 7900 is a 3 terminal, negative, fixed voltage integrated circuit regulator. Mc 7800 and Mc 7900 series requires no external components. The input voltage must be at least two volts higher than the output voltage capacitor c1 is required if the regulator is located far from the power supply. Capacitor c2 improve the transient response. Both series available in To-220 plastic package and T01-3 metal package.

8,36 Block diagram of Mc 7800 and Mc7900 regulator: The unregulated input voltage is fed to the control element and the reference voltage. The output voltage is sampled and fed into one of the error amplifier inputs. The other error amplifier input connected to the reference voltage. When the error amplifier senses a difference between

the reference and sampling voltages it acts upon the control element to correct the error by dropping a greater portion of the input voltage across the control element. The control element is a transistor which acts as a variable registers, in which the resistance is controlled by the error amplifier. The input voltage however must not be large enough to exceed the regulator power dissipation specification. Both series have an internal protection circuit, a current limiting circuit, and a safe-area protection circuit. The safe-area protection circuit limits the regulator output voltage when the input voltage is too higher ensuring that the pass transistor control element operates within its allowed voltage and current ranges.

8,37POWER SUPPLY

7805 IN OUT COM

+5V

2
1000uF

25V
IN4007

100uF

0.1uF

25V

DISC

GROUND

230V/9V-0-9V

1A

IN4007 1000uF
+ +

25V 1 2 COM 3 IN OUT 7905

100uF

25V

0.1uF

DISC -5V

SUGGESTIONS FOR IMPROVEMENTS

SUGGESTIONS FOR IMPROVEMENTS

The project works very well and functions as constrained by the design. Though the project works satisfactorily, it has to be improved in so many ways and then it will reach the professional standards.

First of all the system must be built around a dedicated PCB. Dedicated PCB especially developed for this purpose will improve the efficiency of the system and will be more reliable. In our project the range of the sound produced can reach only within a short distance however by using a transmitter the range can be extended to long distances.

APPLICATIONS

APPLICATIONS

The Project has been designed with the idea of developing a dedicated application. Therefore the very application of the project is quite obvious. However we can think of developing the same project for related other applications as well. Inflammable gas leakage is a general hazard that is applicable not just to moving vehicles such as cars, but the same danger is encountered in many places like, domestic kitchens, hotel kitchen yards, gas storage go downs, gas furnace based other industrial process plants etc. Therefore, the project can be suggested in all such areas. Specific sensors are available to check the presence of such gas leakages.

CONCLUSION

CONCLUSION

The project work has been completed successfully. The project work functions satisfactorily as per the design. The project work was developed after conducting a number of experiments before finalizing the design work, this reduced the bottle necks and we did not face much difficulty in the final integration process. In general the entire development of the project work was educative and we could gain a lot of experience by way of doing the project practically. We could understand the practical constraints of developing such systems which of which we have studied by way of lectures in the theory classes. It was satisfying to see so many theoretical aspects work before us in real life practice of which we have heard through lectures and of which we have studied in the books.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. Electronic Principles

Albert Paul Malvino.

2. Communication Engineering George Kennedy. 3. Linear Integrated Circuits 4. IC Data Sheets Sharma. Manufacturers Manuals.