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CHAPTER 1 INTRODUCTION
Automatic monitoring and control has increasingly found application in the recent past in systems realting to various applications. Their importance has grown over the years where with the implementation of more and more complex systems. The present day systems are employed in almost every field from basic human daily needs to Space programmes. With the increasing use of such systems, their operational features have gained increased importance in the meantime. For a particular application, a variety of systems with varying features will be available in the market. A system is chosen for a particular application depending on its features with is best suited for the specific application. Operating temperature, Frequency, Efficiency, Response time, Compatibility, Flexibility etc are some of the parameters that are considered for selecting a particular system. Operating temperature is one parameter which is of paramount importance in idustrial applications. Desired operation is mostly obtained within a specified temperature range only. But, in most systems temperature varies due to different factors like continued operation, varying loads, system faults etc. Thus temperature needs to be monitored and controlled to ensure the efficient operation of sensitive systems. Hence, we choose temperature as a measurend.
Remote Section
Heat
ADC
MCU PIC16F877A
ASK Rx 49.53MHz
Decoder SM6135W
Buffer ULN2803
RF Module 434MHz
Decoder HT12D
MCU PIC18F4550
9V
Power Supply
5V 3.3V
Encoder SM6136B
ASK Tx 49.53MHz
2.1.4 RF Module The data stream from the Encoder is transmitter by the RF module at 434MHz through the antenna connected to it. The RF module used here is of low cost. 2.1.5 ASK Receiver The transmitted data from the Control Room for controlling the temperature as required is received at the remote location by the ASK Receiver. The transmission and reception of the control signals is at 49.53MHz. 2.1.6 Decoder The decoder IC SM6135W is used to decode the received signals from the Control room to generate the necessary control signals as required. 2.1.7 Buffer High-Voltage, High-Current Darlington arrays IC ULN2803 is used as a Buffer. The output of the buffer is used for various applications like driving a motor, driving the relay etc. 2.2 Control Room Section 2.2.1 RF Module The transmitted signal from the Remote location is received at the Control room at a frequency of 434MHz. 2.2.2 Decoder Low power, high noise immunity HT12D is used to decode the received signal. The decoder first check whether the address matches. Decoding is initiated once the address is found to match.
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2.2.3 Microcontroller Here microcontroller PIC18F4550 is used as the master controller. The decoded signal are sent to the controller. The controller works on synchronisation with the transmitter. The Microcontroller is used to display the parameter to the LCD and generate the necessary control signals for transmission. The microcontroller code specifies certain temperature ranges and the action to be carried out for each case. 2.2.4 LCD The LCD is used to display the measured temperature. A 16x2 LCD array is used. 2.2.5 Encoder Here encoder SM6136B is used to encode the output of the controller. The output of controller depends on the temperature range into which the sensed temperature falls as specified. 2.2.6 USB Port The main feature of PIC18F4550 is that it provides an internal USB Controller. This feature is utilized here to specify the temperature ranges for controlling as required. The port is also used to burn the program into the controller. Hence the need of a seperate burned is avoided. 2.2.7 ASK Transmitter Here Amplitude Shift Keying (ASK) is made use of for transmitting the control signals back to the remote control for controlling the temperature as required. Hence an ASK transmitter transmitting at 49.53MHz is used it send across the signals to the remote location receiver.
Transmitter Section
Figure 4.1
Figure 4.2
Figure 4.3
Controlled Circuit
Figure 4.4
communication. A simple technique is used for this purpose. At starting of each transmission cycle a synchronisation bit of any value between 0 and F (here 5) is send and checked in the receiver. The ADC output is divided into two nibbles and transmitted one by one with delay to the Encoder. HT12E It converts the parallel data received from PIC16F877A to serial data and is send to a transmitter. ASK Transmitter (434MHz) Low cost ASK transmitter, it cannot support high baud rate. If high baud rate is used, then encoder and decoder modules in the transmitter and receiver respectively can be avoided. ASK Receiver (434MHz) It receives the data transmitted from the transmitter and is sent to decoder. The range is approximately 5 metres. HT12D It decodes the serial data from the receiver and converts into parallel data which is then sent to PIC18F4550. PIC18F4550 It contains an in-built USB controller. The PIC is configured to work in two modes: 1. Bootloader mode 2. User Mode 1. Bootloader mode: A bootloader program is burned through ICSP and the Pin RB4 is the mode selection pin. If it is 1, then User mode is selected and if it is 0, it selects Bootloader mode.
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In Bootloader mode we can configure the controller or burn the program or read/write data to system using USB port. 2. User mode: In this mode, the program is executed. The basic configuration bits are configured as follows: > PLL division is set as 1 (4MHz crystal). > CPU division is disabled. Due to this configuration bit, PIC is working in 48MHz. Externally we use a 4MHz crystal. LCD A 16x2 LCD is connected in Port B. The basic configuration for LCD is: > Pin 1 is connected to VSS. > Pin 2 is connected to VDD. > Pin 3 is connected to 100K (pot.) for adjusting the contrast. It has 8 bits D0-D7 for data and Pins 15 and 16 are used for backlight purpose. SM6136B The output from Port D of PIC18F4550 is connected to the Encoder. It converts these inputs into serial format with its framing. ASK Transmitter (49.53MHz) This section contains two parts: 1. Crystal Oscillator 2. ASK Modulator The output from Encoder is mixed with output of crystal oscillator and is given to ASK modulator
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and is transmitted from antennae. In this section two high frequency transmitters, C945 are used. ASK Receiver (49.53MHz) It receives the data from transmitter to reconstruct the original signal with the help of C380 transistor and tuned circuit. It is tuned to 49.53MHz. SM6135W The output of receiver is given to decoder. It decodes the data and output is given to ULN2804. The output of ULN2804 is connected to cooling fan and a relay. The remaining outputs can be used for any other applications. Power Supply We are using 9V battery as Power source and 7805 is used for regulating it to 5V (given to Microcontroller), Zener voltage regulator are used to obtain 3.3V for SM6136B and SM6135W.
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switched on iron box. The heat produced by the iron box must be sufficiently high that the impression of the layout is copied on to the copper clad surface. 4. ETCHING OF THE BOARD When the board is ready for etching, it is placed in the Ferric Chloride solution of required concentration. It is checked in regular intervals to prevent over etching and successive damage to the part. After the etching is complete the board is taken out of the etch and washed in water to remove the excess ferric chloride. The D13X NC Thinner is applied to remove any dew or paint material on copper tracks. Then the sheet is cleaned by using steel scrubber and washed again in water. Now the copper lines are exposed and hence the body is checked with the magnifying glass to see whether all the lines in the layout are clearly formed. Now the board is ready for tinning. 5. DRILLING The next process is drilling, In this the holes of required sizes are drilled in the PCB wherever needed, using an PCB drilling machine. 6. FINISHING
In the process after drilling holes on PCB, the board is taken and a light coat of air dying insulating varnish is applied to the bottom side carefully avoiding the pad areas The PCB is then left till the insulating varnish dry up. The application of the insulating varnish prevents any type of oxidation on the track further proving better safeguard to the tracks after tinning.
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SOLDERING Soldering is the process of joining two or more or dissimilar metals by melting another metal having low melting points. SOLDERING TOOLS Soldering Iron It is the tool used to melt the solder and apply at the joints in the circuit. It operates in 230V main supply. The normal power ratings of the soldering iron are 10W, 25W, 35W, 65W and 125W. The iron bit at the top of it gets heated up within a few minutes. 10W and 25W soldering irons are sufficient for light duty works. Soldering Station The soldering station consists of a handheld hot air blow gun and the base station comprising of air flow and temperature controls to the hot air blow gun. Tip temperature is maintained by feedback control loops. Soldering guns usually have a trigger switch which controls the AC power.
MAKING SOLDERING JOINTS Hold the soldering like a pen, near the base of the handle. Remember to never touch the hot element or tip. Touch the soldering iron onto the joint to be made. Make sure it touches both the
component lead and the track. Hold the tip there for a few seconds. Feed a little solder on the joint. It should flow smoothly onto the lead and track to
form a volcano shape. Make sure you supply the solder to the joint, not to the iron.
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Remove the solder, then the iron, while keeping the joint still. Allow the joint a few
seconds to cool before you move the circuit board. Inspect the joint closely. It should look shiny and have a volcano shape. If not, you
will need to reheat it and feed in a little more solder. This time ensure that both the lead and track are heated fully before applying solder. DESOLDERING It is the removal of the solder from previously soldered joint. There are two ways to remove the solder. USING DESOLDERING PUMP (SOLDER SUCKER) De-solder pump is a commonly used device for this purpose. When the solder melts by the action of the soldering iron, the trigger on the de-solder pump should be activated to create a vacuum. This vacuum pulls the solder into the tube. Set the pump by pushing the spring loaded plunger down until it locks. Apply both pump nozzle and the tip of your soldering iron to the joint. Wait a second or two for the solder to melt. Then press the button on the pump to release plunger and suck the molten solder into the tool. Repeat if necessary to remove as much solder as possible. The pump will need emptying occasionally by unscrewing the nozzle.
SAFETY PRECUATIONS Never touch the element or tip of the soldering iron. They are very hot (about 673K) and will you a nasty burn. Take great care to avoid touching the mains flex with the tip of the iron. The iron
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should have a heatproof flex for extra protection. Ordinary plastic flex melts immediately if touched by a hot iron and there is a risk of burns and electric shock. Always return the soldering iron to its stand when it is not in use. Allow joints a minute or so to cool down before you touch them. Work in a well ventilated area. The smoke formed as you melt the solder is mostly from the flux and quite irritating. Avoid breathing it by keeping your head to the side of, not, above your work. Wash your hands after using solder.
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Different editions of EAGLE, 1. Professional Edition 2. Standard Edition 3. Light Edition for our application we chose the light edition. The following restrictions apply to the EAGLE Light Edition: The board area is restricted to 100 x 80 mm (about 3.9 x 3.2 inches). Outside this area it is not possible to place packages and draw signals. Only two signal layers can be used (no inner layers). A schematic can consist of only one single sheet.
Larger Layout and Schematic files can be printed with the higher editions. The CAM processor can generate manufacturing data as well. It is not possible to combine modules of different editions. The Light Edition is available as Freeware for testing, evaluation, and noncommercial use.
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CHAPTER 10 FLOWCHART
Transmitter Section Start Port Initialization ADC Configuration Read from ADC Send Synchronization bit Send lower Nibble
Delay
Delay
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Receiver Section
Start
Is RB3==1 Yes
No
Bootloader Mode
User Mode
LCD Initialization
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C1
Delay
Reconstruct byte
Convert to Celsius
Send to LCD
C2
25
9V
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Component Name Resistor (1/4 Watts) Capacitor i. Disc ii. Electrolytic Inductor Transistor Crystal IC base i. 16 pin ii. 40 pin IC i. SM6136B ii. SM 6135W iii. HT12D iv. HT12E v. PIC16F877A vi. PIC18F4550 vii. IC7805 viii. ULN2805 ix. LM35 RF Module LED LCD 16x2 Connectors i. USB ii. 8 pin connectors iii. 6 pin connectors iv. 2 pin connectors v. Battery connector USB Cable
Price/Unit (Rs.) 0.25 0.50 1.50 5.00 8.00 10.00 2.00 12.00 35.00 35.00 40.00 40.00 120.00 285.00 15.00 20.00 35.00 300.00 1.50 150 5.00 10.00 10.00 5.00 8.00 50.00
Quantity (No's) 30 20 5 5 3 3 4 2 1 1 1 1 1 1 2 1 1 1 4 1 1 2 1 2 2 1
Total Price (Rs.) 7.50 10.00 7.50 25.00 24.00 30.00 8.00 24.00 35.00 35.00 40.00 40.00 120.00 285.00 30.00 20.00 35.00 300.00 6.00 150 5.00 20.00 10.00 10.00 16.00 50.00
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