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The systems have been implemented in various companies and have seen
the positive results. The quality of the product mainly depends on the design of the
product, manufacturing system used and the continuous feedback which is used to
improve the quality. Automated Manufacturing system combines all these aspects to
change the raw material into a finished product. The result is that product quality
increases and decreases the overheads on the product thus the cost of product
decreases.
AMS combines the design aspect with manufacturing one to give a sound and
effective product. The efficiency of product depends on how it has been assembled.
Use of automated assembly system increases the scope of perfect fitting of the
product to greater extent. Also the paper contains Automated Material Handling and
Storage devices. The automated QC process will increase the rate of inspection and
rate of passing defective parts decreases. It also facilitates inspection of number of
products with high rate and greater accuracy.
INTRODUCTION
1
In this, motor can be operated remotely with the help of programming that is
done in C language. The flexibility is allowed in the motor controlled i.e. quick
reversal, speed control, precise rotation of the stepper motor through required step
angle. In this project wireless link between computer and motor is used. This system
provides movement in space for executing various tasks with proper interface to other
equipments machines and processes. It is having accuracy with which it can perform
its tasks
The project consists of wireless motor control using personal computer. As
project touches to three separate subjects i.e. Machine, Embedded system and
Wireless communication. To get an overview of project an introduction to each of
above mentioned subject is necessary. In next three chapter you will get an idea about
these subjects.
In the 1970 Occupation Safety and Health Act (OSHA) protested the workers
from working under harmful conditions. Therefore employing workers for working in
hazardous conditions like heat treatment, spray painting is stopped. Also with the use
of old technology during manufacturing the product there more scrap produced due to
trial and error method and product requires more time to get ready for delivering to
customers. i.e. more manufacturing lead time.
2
Harrington introduced the new term for automation called “COMPUTER
INTEGRATED MANUFACTURING”.
3. Industrial robots.
1) Fixed automation-
2) Programmable automation-
“In this system the production equipment is designed with the capability to
change the sequence of operations to accommodate different product configuration”.
The operation sequence is controlled by the program, which is set of instructions
coded so that system can read and interpret. New programs can be prepared and
entered into the equipment to produce the new product.
3) Flexible automation-
4
between input and output? What is the function of the process? What are the up-
stream and down-stream operations in the production sequence and can them be
combined with the process under consideration.
Once the processes have been reduced to its simplest form then automation
can be considered. The possible forms of automation i.e. use of computers and
electronics,
I. Hand truck
IV. Conveyors
5
1.5.1 Conveyor System –
Types of conveyors –
a) Rolled conveyors :
c) Belt conveyors:
c) Chain conveyors :
6
Chain conveyors are made of loops of endless chain in an over-
and-under configuration around the powered sprockets at the end of the pathway.
There may be one or more chains working parallel. The chain slides along the channel
or they use rollers to slide the channel. The loads are generally ride along the top of
the chain.
d) Slat conveyor :
The slat conveyors uses individual platform, called slats that are
connected to a continuously moving chain. The drive mechanism is powered by chain
and the load is placed on the flat surface of the slat.
Types:
a) Driverless trains –
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truck is the forklift AGV. This vehicle can achieve significant vertical movement of
its fork to reach loads to shelves.
This type is used to move unit load from one station to another
station. They are equipped with automatic loading and unloading by means of
powered rollers. They are of two types: Light load AGV and Assembly line AGV.
Assembly line AGV serves for heavy duty purposes.
Simply put, wireless is any communications method that does not depend on wires
(metallic or fiber) for the transmission of communications signals. Wireless
communications provides “connectivity” between two or more devices (a transmitter
and a receiver) enabling them to exchange information. The fundamental difference
between wireless communication and other “wired” forms of communications is the
medium over which the encoded energy containing information is transferred between
the transmitter and receiver. In wireless systems energy transfer occurs through air or
through free space without a physical connection between the devices. The energy
transfer can be visible optical radiation, invisible infrared, ultraviolet or radio
frequency (RF) to name a few.
8
2. LITERATURE SURVEY:
Stepper motors operate differently from normal DC motors, which simply spin when
voltage is applied to their terminals. Stepper motors, on the other hand, effectively
have multiple "toothed" electromagnets arranged around a central metal gear, as
shown at right. To make the motor shaft turn, first one electromagnet is given power,
which makes the gear's teeth magnetically attracted to the electromagnet's teeth.
When the gear's teeth are thus aligned to the first electromagnet, they are slightly
offset from the next electromagnet. So when the next electromagnet is turned on and
the first is turned off, the gear rotates slightly to align with the next one, and from
there the process is repeated. Each of those slight rotations is called a "step." In that
way, the motor can be turned a
The top electromagnet (1) is turned off, The bottom electromagnet (3) is charged;
9
This results in a rotation of 3.6°.
the teeth in the sprocket will have rotated by one tooth position;
Precise angle. There are two basic arrangements for the electromagnetic coils: bipolar
and unipolar.
In a unipolar stepper motor, there are four separate electromagnets. To turn the motor,
first coil "1" is given current, then it's turned off and coil 2 is given current, then coil
3, then 4, and then 1 again in a repeating pattern. Current is only sent through the coils
in one direction; thus the name unipolar.
10
A unipolar stepper motor will have 5 or 6 wires coming out of it. Four of those wires
are each connected to one end of one coil. The extra wire (or 2) is called "common."
To operate the motor, the "common" wire(s) is(are) connected to the supply voltage,
and the other four wires are connected to ground through transistors, so the transistors
control whether current flows or not. A microcontroller or stepper motor controller is
used to activate the transistors in the right order. This ease of operation makes
unipolar motors popular with hobbyists; they are probably the cheapest way to get
precise angular movements.
(For the experimenter, one way to distinguish common wire from a coil-end wire is
by measuring the resistance. Resistance between common wire and coil-end wire is
always half of what it is between coil-end and coil-end wires. This is due to the fact
that there is actually twice the length of coil between the ends and only half from
center (common wire) to the end.)
There are only two coils, and current must be sent through a coil first in one direction
and then in the other direction; thus the name bipolar. Bipolar motors need more than
4 transistors to operate them, but they are also more powerful than a unipolar motor of
the same weight. To be able to send current in both directions, engineers can use an
H-bridge to control each coil or a step motor driver chip.
Theory
A step motor can be viewed as a DC motor with the number of poles (on both rotor
and stator) increased, taking care that they have no common denominator.
Additionally, soft magnetic material with many teeth on the rotor and stator cheaply
multiplies the number of poles (reluctance motor). Like an AC synchronous motor, it
is ideally driven by sinusoidal current, allowing a step less operation, but this puts
some burden on the controller. When using an 8-bit digital controller, 256 micro steps
per step are possible. As a digital-to-analog converter produces unwanted ohmic heat
in the controller, pulse-width modulation is used instead to regulate the mean current.
Simpler models switch voltage only for doing a step, thus needing an extra current
limiter: for every step, they switch a single cable to the motor. Bipolar controllers can
switch between supply voltage, ground, and unconnected. Unipolar controllers can
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only connect or disconnect a cable, because the voltage is already hard wired.
Unipolar controllers need center-tapped windings.
It is possible to drive unipolar stepper motors with bipolar drivers. The idea is to
connect the output pins of the driver to 4 transistors. The transistor must be grounded
at the emitter and the driver pin must be connected to the base. Collector is connected
to the coil wire of the motor.
Stepper motors are rated by the torque they produce. Synchronous electric motors
using soft magnetic materials (having a core) have the ability to provide position
holding torque (called detent torque, and sometimes included in the specifications)
while not driven electrically. To achieve full rated torque, the coils in a stepper motor
must reach their full rated current during each step. The voltage rating (if there is one)
is almost meaningless. The motors also suffer from EMF, which means that once the
coil is turned off it starts to generate current because the motor is still rotating. There
needs to be an explicit way to handle this extra current in a circuit otherwise it can
cause damage and affect performance of the motor.
2.1.4 Applications
Computer-controlled stepper motors are one of the most versatile forms of positioning
systems, particularly when digitally controlled as part of a servo system. Stepper
motors are used in floppy disk drives, flatbed scanners, printers, plotters and many
more devices. Note that hard drives no longer use stepper motors to position the
read/write heads, instead utilizing a voice coil and servo feedback for head
positioning.
Stepper motors can also be used for positioning of valve pilot stages, for fluid control
systems.
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2.2 DC MOTOR CONTROL
2.2.1 Principle :
If the shaft of a DC motor is turned by an external force, the motor will act like a
generator and produce an Electromotive force (EMF). During normal operation, the
spinning of the motor produces a voltage, known as the counter-EMF (CEMF) or
back EMF, because it opposes the applied voltage on the motor. This is the same
EMF that is produced when the motor is used as a generator (for example when an
electrical load (resistance) is placed across the terminals of the motor and the motor
shaft is driven with an external torque). Therefore, the voltage drop across a motor
consists of the voltage drop, due to this CEMF, and the parasitic voltage drop
resulting from the internal resistance of the armature's windings. The current through
a motor is given by the following equation:
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I = (Vapplied − Vcemf) / Rarmature
P = I * (Vapplied − Vcemf)
When current passes through the coil wound around a soft iron core the side of the
positive pole is acted upon by an upwards force, while the other side is acted upon by
a downward force. According to Fleming's left hand rule, the forces cause a turning
effect on the coil making it rotate; to make the motor rotate in a constant direction
"direct current" commutators make the current reverse in direction every half a cycle
thus causing the motor to rotate in the same direction. The problem facing the motor
is when the plane of the coil is parallel to the magnetic field; i.e. the turning effect is
ZERO-when coil is at 90 degree from its original position-yet, the coil continues to
rotate by inertia.
Since the CEMF is proportional to motor speed, when an electric motor is first started
or is completely stalled, there is zero CEMF. Therefore the current through the
armature is much higher. This high current will produce a strong magnetic field which
will start the motor spinning. As the motor spins, the CEMF increases until it is equal
to the applied voltage, minus the parasitic voltage drop. At this point, there will be a
smaller current flowing through the motor. Basically, the following three equations
can be used to find the speed, current, and back EMF of a motor under a load:
Load = Vcemf * I
14
direction of a wound field DC motor can be changed by reversing either the field or
armature connections but not both. This is commonly done with a special set of
contactors (direction contactors).
Since the series-wound DC motor develops its highest torque at low speed, it is often
used in traction applications such as electric locomotives, and trams. Another
application is starter motors for petrol and small diesel engines. Series motors must
never be used in applications where the drive can fail (such as belt drives). As the
motor accelerates, the armature (and hence field) current reduces. The reduction in
field causes the motor to speed up (see 'weak field' in the last section) until it destroys
itself. This can also be a problem with railway motors in the event of a loss of
adhesion since, unless quickly brought under control, the motors can reach speeds far
higher than they would do under normal circumstances. This can not only cause
problems for the motors themselves and the gears, but due to the differential speed
between the rails and the wheels it can also cause serious damage to the rails and
wheel treads as they heat and cool rapidly. Field weakening is used in some electronic
controls to increase the top speed of an electric vehicle. The simplest form uses a
15
contactor and field weakening resistor, the electronic control monitors the motor
current and switches the field weakening resistor into circuit when the motor current
reduces below a preset value (this will be when the motor is at its full design speed).
Once the resistor is in circuit, the motor will increase speed above its normal speed at
its rated voltage. When motor current increases, the control will disconnect the
resistor and low speed torque is made available.
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2.3 INDUCTION MOTOR :
17
2.3.1Stator
The stator is the outer body of the motor which houses the driven
windings on an iron core. In a single speed three phase motor design, the
standard stator has three windings, while a single phase motor typically
has two windings.
The winding configuration, slot configuration and lamination steel all have an
effect on the performance of the motor. The voltage rating of the motor
is determined by the number of turns on the stator and the power rating
of the motor is determined by the losses which comprise copper loss and
iron loss, and the ability of the motor to dissipate the heat generated by
the losses. The stator design determines the rated speed of the motor and
most of the full load, full speed characteristics.
2.3.2 Rotor
18
The Rotor comprises a cylinder made up of round laminations pressed onto the
motor shaft, and a number of short-circuited windings. The rotor
windings are made up of rotor bars passed through the rotor, from one
end to the other, around the surface of the rotor. The bars protrude
beyond the rotor and are connected together by a shorting ring at each
end. The bars are usually made of aluminium or copper, but sometimes
made of brass. The position relative to the surface of the rotor, shape,
cross sectional area and material of the bars determine the rotor
characteristics. Essentially, the rotor windings exhibit inductance and
resistance, and these characteristics can effectively be dependant on the
frequency of the current flowing in the rotor.
A bar with a large cross sectional area will exhibit a low resistance,
while a bar of a small cross sectional area will exhibit a high resistance.
Likewise a copper bar will have a low resistance compared to a brass
bar of equal proportions.
Positioning the bar deeper into the rotor, increases the amount of iron
around the bar, and consequently increases the inductance exhibited by
the rotor. The impedance of the bar is made up of both resistance and
inductance, and so two bars of equal dimensions will exhibit different
A.C. impedance depending on their position relative to the surface of the
rotor. A thin bar which is inserted radialy into the rotor, with one edge
near the surface of the rotor and the other edge towards the shaft, will
effectively change in resistance as the frequency of the current changes.
This is because the A.C. impedance of the outer portion of the bar is
lower than the inner impedance at high frequencies lifting the effective
impedance of the bar relative to the impedance of the bar at low
frequencies where the impedance of both edges of the bar will be lower
and almostequal.
The rotor design determines the starting characteristics.
2.3.3Equivalent Circuit
19
The induction motor can be treated essentially as a transformer for analysis.
The induction motor has stator leakage reactance, stator copper loss
elements as series components, and iron loss and magnetizing
inductance as shunt elements. The rotor circuit likewise has rotor
leakage reactance, rotor copper (aluminium) loss and shaft
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Power as series elements.
The transformer in the centre of the equivalent circuit can be eliminated
by adjusting the values of the rotor components in accordance with the
effective turns ratio of the transformer.
From the equivalent circuit and a basic knowledge of the operation of
the induction motor, it can be seen that the magnetizing current
component and the iron loss of the motor are voltage dependant, and not
load dependant. Additionally, the full voltage starting current of a
particular motor is voltage and speed dependant, but not load
dependant.
The magnetizing current varies depending on the design of the motor.
For small motors, the magnetizing current may be as high as 60%, but
for large two pole motors, the magnetizing current is more typically 20 -
25%. At the design voltage, the iron is typically near saturation, so the
iron loss and magnetizing current do not vary linearly with voltage with
small increases in voltage resulting in a high increase in magnetizing
current and iron loss.
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2.3.4 Starting Characteristics.
In order to perform useful work, the induction motor must be started
from rest and both the motor and load accelerated up to full speed.
Typically, this is done by relying on the high slip characteristics of the
motor and enabling it to provide the acceleration torque.
Induction motors at rest, appear just like a short circuited transformer,
and if connected to the full supply voltage, draw a very high current
known as the "Locked Rotor Current". They also produce torque which
is known as the "Locked Rotor Torque". The Locked Rotor Torque
(LRT) and the Locked Rotor Current (LRC) are a function of the
terminal voltage to the motor, and the motor design. As the motor
accelerates, both the torque and the current will tend to alter with rotor
speed if the voltage is maintained constant.
The starting current of a motor, with a fixed voltage, will drop very
slowly as the motor accelerates and will only begin to fall significantly
when the motor has reached at least 80% full speed. The actual curves
for induction motors can vary considerably between designs, but the
general trend is for a high current until the motor has almost reached
full speed. The LRC of a motor can range from 500% Full Load
Current (FLC) to as high as 1400% FLC. Typically, good motors fall in
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the range of 550% to 750% FLC.
23
The starting torque of an induction motor starting with a fixed voltage,
will drop a little to the minimum torque known as the pull up torque as
the motor accelerates, and then rise to a maximum torque known as the
breakdown or pull out torque at almost full speed and then drop to zero
at synchronous speed. The curve of start torque against rotor speed is
dependant on the terminal voltage and the motor/rotor design.
The LRT of an induction motor can vary from as low as 60% Full Load
Torque (FLT) to as high as 350% FLT. The pull-up torque can be as low
as 40% FLT and the breakdown torque can be as high as 350% FLT.
Typical LRTs for medium to large motors are in the order of 120% FLT
to 280% FLT.
The power factor of the motor at start is typically 0.1 - 0.25, rising to a maximum as
the motor accelerates, and then falling again as the motor approaches full speed.
A motor which exhibits a high starting current, i.e. 850% will generally produce a low
starting torque, whereas a motor which exhibits a low starting current, will usually
produce a high starting torque. This is the reverse of what is generally expected.
The induction motor operates due to the torque developed by the interaction of the
stator field and the rotor field. Both of these fields are due to currents which have
resistive or in phase components and reactive or out of phase components. The torque
developed is dependant on the interaction of the in phase components and
consequently is related to the I2R of the rotor. A low rotor resistance will result in the
current being controlled by the inductive component of the circuit, yielding a high out
of phase current and a low torque.
Figures for the locked rotor current and locked rotor torque are almost always quoted
in motor data, and certainly are readily available for induction motors. Some
manufactures have been known to include this information on the motor name plate.
One additional parameter which would be of tremendous use in data sheets for those
who are engineering motor starting applications, is the starting efficiency of the
motor. By the starting efficiency of the motor, I refer to the ability of the motor to
convert amps into newton meters. This is a concept not generally recognized within
the trade, but one which is extremely useful when comparing induction motors. The
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easiest means of developing a meaningful figure of merit, is to take the locked rotor
torque of the motor (as a percentage of the full load torque) and divide it by the
locked rotor current of the motor (as a percentage of the full load current).
If the terminal voltage to the motor is reduced while it is starting, the current
drawn by the motor will be reduced proportionally. The torque developed by the
motor is proportional to the current squared, and so a reduction in starting voltage will
result in a reduction in starting current and a greater reduction in starting torque. If the
start voltage applied to a motor is halved, the start torque will be a quarter; likewise a
start voltage of one third will result in a start torque of one ninth.
25
2.3.5 Running Characteristics.
Once the motor is up to speed, it operates at low slip, at a speed
determined by the number of stator poles. The frequency of the current
flowing in the rotor is very low. Typically, the full load slip for a
standard cage induction motor is less than 5%. The actual full load slip
of a particular motor is dependant on the motor design with typical full
load speeds of four pole induction motor varying between 1420 and 1480
RPM at 50 Hz. The synchronous speed of a four pole machine at 50 Hz
is 1500 RPM and at 60 Hz a four pole machine has a synchronous speed
of 1800 RPM.
The induction motor draws a magnetizing current while it is operating.
The magnetizing current is independent of the load on the machine, but
is dependant on the design of the stator and the stator voltage. The
actual magnetizing current of an induction motor can vary from as low
as 20% FLC for large two pole machines to as high as 60% for small
eight pole machines. The tendency is for large machines and high speed
machines to exhibit a low magnetizing current, while low speed
machines and small machines exhibit a high magnetizing current. A
typical medium sized four pole machine has a magnetizing current of
about 33% FLC.
A low magnetizing current indicates a low iron loss, while a high
magnetizing current indicates an increase in iron loss and a resultant
reduction in operating efficiency.
The resistive component of the current drawn by the motor while
operating, changes with load, being primarily load current with a small
current for losses. If the motor is operated at minimum load, i.e. open
shaft, the current drawn by the motor is primarily magnetizing current
and is almost purely inductive. Being an inductive current, the power
factor is very low, typically as low as 0.1. As the shaft load on the motor
is increased, the resistive component of the current begins to rise. The
average current will noticeably begin to rise when the load current
approaches the magnetizing current in magnitude. As the load current
increases, the magnetizing current remains the same and so the power
factor of the motor will improve. The full load power factor of an
26
induction motor can vary from 0.5 for a small low speed motor up to 0.9
for a large high speed machine.
The losses of an induction motor comprise: iron loss, copper loss,
windage loss and frictional loss. The iron loss, windage loss and
frictional losses are all essentially load independent, but the copper loss
is proportional to the square of the stator current. Typically the
efficiency of an induction motor is highest at 3/4 load and varies from
less than 60% for small low speed motors to greater than 92% for large
high speed motors. Operating power factor and efficiencies are generally
quoted on the motor data sheets.
27
There are a number of design/performance classifications which are somewhat
uniformly accepted by different standards organizations. These design
classifications apply particularly to the rotor design and hence affect the
starting characteristics of the motors. The two major classifications of
relevance here are design A, and design B.
Design A motors have a shallow bar rotor, and are characterised by a
very high starting current and a low starting torque. Typical values are
850% current and 120% torque. Shallow bar motors usually have a low
slip, i.e. 1480 RPM.
Design B motors have a deeper bar rotor and are characterised by
medium start current and medium starting torque. Typical design B
values are 650% current and 180% torque. The slip exhibited by design
B motors is usually greater than the equivalent design A motors. i.e.
1440 RPM.
Design F motors are often known as Fan motors having a high rotor
resistance and high slip characteristics. The high rotor resistance
enables the fan motor to be used in a variable speed application where
the speed is reduced by reducing the voltage. Design F motors are used
primarily in fan control applications with the motor mounted in the air
flow. These are often rated as AOM or Air Over Motor machines.
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2.3.7 Single phase motors.
In order for a motor to develop a rotating torque in one direction, it is
important that the magnetic field rotates in one direction only. In the
case of the three phase motor, there is no problem and the field follows
the phase sequence. If voltage is applied to a single winding, there are
still multiples of two poles which alternate between North and South at
the supply frequency, but there is no set rotation for the vectors. This
field can be correctly considered to be two vectors rotating in opposite
directions. To establish a direction of rotation for the vector, a second
phase must be added. The second phase is applied to a second winding
and is derived from the first phase by using the phase shift of a capacitor
in a capacitor start motor, or inductance and resistance in an induction
start motor. (sometimes known as a split phase motor.) Small motors use
techniques such as a shaded pole to set the direction of rotation of the
motor.
29
2.3.7 Slip Ring Motors.
Slip ring motors or wound rotor motors are a variation on the standard
cage induction motors. The slip ring motor has a set of windings on the
rotor which are not short circuited, but are terminated to a set of slip
rings for connection to external resistors and contactors. The slip ring
motor enables the starting characteristics of the motor to be totally
controlled and modified to suit the load. A particular high resistance can
result in the pull out torque occurring at almost zero speed providing a
very high locked rotor torque at a low locked rotor current. As the
motor accelerates, the value of the resistance can be reduced altering the
start torque curve in a manner such that the maximum torque is
gradually moved towards synchronous speed. This results in a very high
starting torque from zero speed to full speed at a relatively low starting
current. This type of starting is ideal for very high inertia loads allowing
the machine to get to full speed in the minimum time with minimum
current draw.
The down side of the slip ring motor is that the slip rings and brush
assemblies need regular maintenance which is a cost not applicable to
the standard cage motor. If the rotor windings are shorted and a start is
attempted, i.e. the motor is converted to a standard induction motor, it
will exhibit an extremely high locked rotor current, typically as high as
1400% and a very low locked rotor torque, perhaps as low as 60%. In
most applications, this is not an option.
Another use of the slip ring motor is as a means of speed control. By
modifying the speed torque curve, by altering the rotor resistors, the
speed at which the motor will drive a particular load can be altered.
This has been used in winching type applications, but does result in a lot
of heat generated in the rotor resistors and consequential drop in overall
efficiency.
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2.4 JUSTIFICATION
In this project, we are trying to implement a motor control system which can
control the Induction motor , DC motor , stepper motor placed at the Remote location
In case of the stepper motor control we can control step angle with great degree of
accuracy. A D.C, motor speed can be controlled smoothly. A motor can be quickly
reversed in rotation, & stopped. . This project will certainly provide a window into the
fascinating world of Automation.
The objective is to control the all motors of the higher rating like the three
phase motor through a computer interfaced system. Considering to techno-economical
constraints the project will be a prototype having fewer features as compared to
commercially available one.
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3. DEVELOPMENT OF SYSTEM
RF RF
Receiver Transmitter
4:16
Decoder Motor driver
Converter
Motors
1. Stepper
2. D.C.
3.Induction
32
This system is divided into three sections:
1. Remote Section
3. Motor Section.
1. Remote Section:
This is a PC based control system through which you can control your system.
This contains RF receiver along with decoder motor control system. The motor can be
controlled with help of programming in C language.
3 . Motor Section:
The motor section consist of the three motors like DC, stepper ,Induction
& driver circuit which consists of the motor controlling circuit using ULN
2003.
Here after we will introduce you various hardware components required in the
project.
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3.2 PARALLEL PORT OF PC
The Parallel Port is the most commonly used port for interfacing home made
projects. This port will allow the input of up to 9 bits or the output of 12 bits at any
one given time, thus requiring minimal external circuitry to implement many simpler
tasks. The port is composed of 4 control lines, 5 status lines and 8 data lines. It's
found commonly on the back of your PC as a D-Type 25 Pin female connector. There
may also be a D-Type 25 pin male connector. This will be a serial RS-232 port and
thus, is a totally incompatible port.
Newer Parallel Port’s are standardized under the IEEE 1284 standard first released in
1994. This standard defines 5 modes of operation which are as follows,
1. Compatibility Mode.
The aim was to design new drivers and devices which were compatible with each
other and also backwards compatible with the Standard Parallel Port (SPP).
Compatibility, Nibble & Byte modes use just the standard hardware available on the
original Parallel Port cards while EPP & ECP modes require additional hardware
34
which can run at faster speeds, while still being downwards compatible with the
Standard Parallel Port. Compatibility mode or "Centronics Mode" as it is commonly
known can only send data in the forward direction at a typical speed of 50 Kbytes per
second but can be as high as 150+ Kbytes a second. In order to receive data, you must
change the mode to either Nibble or Byte mode. Nibble mode can input a nibble (4
bits) in the reverse direction.
Byte mode uses the Parallel's bi-directional feature (found only on some cards) to
input a byte (8 bits) of data in the reverse direction. Extended and Enhanced Parallel
Ports use additional hardware to generate and manage handshaking. To output a byte
to a printer (or anything in that matter) using compatibility mode, the software must:
Check to see is the printer is busy. If the printer is busy, it will not accept any
data, thus any data which is written will be lost.
Take the Strobe (Pin 1) low. This tells the printer that there is the correct data on the
data lines. (Pins 2-9)
Put the strobe high again after waiting approximately 5 microseconds after putting
the strobe low. (Step 3)
This limits the speed at which the port can run at. The EPP & ECP ports get around
this by letting the hardware check to see if the printer is busy and generate a strobe
and /or appropriate handshaking. This means only one I/O instruction need to be
performed, thus increasing the speed. These ports can output at around 1-2 megabytes
per second. The ECP port also has the advantage of using DMA channels and FIFO
buffers, thus data can be shifted around without using I/O instructions.
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3.2.2 Hardware Properties
On the next page is a table of the "Pin Outs" of the D-Type 25 Pin connector and the
Centronics 34 Pin connector. The D-Type 25 pin connector is the most common
connector found on the Parallel Port of the computer, while the Centronics Connector
is commonly found on printers. The IEEE 1284 standard however specifies 3 different
connectors for use with the Parallel Port. The first one, 1284 Type A is the D-Type 25
connector found on the back of most computers. The 2nd is the 1284 Type B which is
the 36 pin Centronics Connector found on most printers. IEEE 1284 Type C however,
is a 36 conductor connector like the Centronics, but smaller. This connector is
claimed to have a better clip latch, better electrical properties and is easier to
assemble. It also contains two more pins for signals which can be used to see whether
the other device connected, has power. 1284 Type C connectors are recommended for
new designs, so we can look forward on seeing these new connectors in the near
future.
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Fig7 D-25 Female Connector
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The above table uses "n" in front of the signal name to denote that the signal is
active low. e.g. nError. If the printer has occurred an error then this line is low. This
line normally is high, should the printer be functioning correctly. The "Hardware
Inverted" means the signal is inverted by the Parallel card's hardware. Such an
example is the Busy line. If +5v (Logic 1) was applied to this pin and the status
register read, it would return back a 0 in Bit 7 of the Status Register.
The output of the Parallel Port is normally TTL logic levels. The voltage
levels are the easy part. The current you can sink and source varies from port to port.
Most Parallel Ports implemented in ASIC, can sink and source around 12mA.
However these are just some of the figures taken from Data sheets, Sink/Source 6mA,
Source 12mA/Sink 20mA, Sink 16mA/Source 4mA, Sink/Source 12mA. As you can
see they vary quite a bit. The best bet is to use a buffer, so the least current is drawn
from the Parallel Port.
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3.2.3 Port addresses
The Parallel Port has three commonly used base addresses. These are listed in
table 2, below. The 3BCh base address was originally introduced used for Parallel
Ports on early Video Cards. This address then disappeared for a while, when Parallel
Ports were later removed from Video Cards. They has now reappeared as an option
for Parallel Ports integrated onto motherboards, upon which their configuration can be
changed using BIOS.
LPT1 is normally assigned base address 378h, while LPT2 is assigned 278h.
However this may not always be the case as explained later. 378h & 278h have
always been commonly used for Parallel Ports. The lower case h denotes that it is in
hexadecimal. These addresses may change from machine to machine.
The following sample program in C, shows how you can read these locations
to obtain the addresses of your printer ports.
#include <stdio.h>
#include <dos.h>
void main(void)
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unsigned int far *ptraddr; /* Pointer to location of Port Addresses */
int a;
address = *ptraddr;
if (address == 0)
else
*ptraddr++;
The table below shows the register addresses of LPT1 & LPT2
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Control register (Base address+0) 0x37a 0x27a
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Fig 9 Flowchart for program on PC
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3.4 RF TRANSMITTER:
The 212 encoders are a series of CMOS LSIs for remote control system
applications. They are capable of encoding information which consists of N address
bits and 12_N data bits. Each address/ data input can be set to one of the two logic
states. The programmed addresses /data are transmitted together with the header bits
via an RF or an infrared transmission medium upon receipt of a trigger signal. The
capability to select a TE trigger on the HT12E or a DATA trigger on the HT12A
further enhances the application flexibility of the 212 series of encoders. The
HT12A additionally provides a 38 kHz carrier for infrared systems.
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45
Table 4 Pin Description of RF Transmitter
3.4.1 Operation
The 212 series of encoders begin a 4-word transmission cycle upon receipt of a
transmission enable (TE for the HT12E or D8~D11 for the HT12A, active low). This
cycle will repeat itself as long as the transmission enable (TE or D8~D11) is held low.
Once the transmissions enable returns high the encoder output completes its final
cycle and then stops as shown below.
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3.4.2 Information word
If L/MB=1 the device is in the latch mode (for use with the latch type of data
decoders). When the transmission enable is removed during a transmission, the
DOUT pin outputs a complete word and then stops. On the other hand, if L/MB=0 the
device is in the momentary mode (for use with the momentary type of data decoders).
When the transmission enable is removed during a transmission, the DOUT outputs a
complete word and then adds 7 words all with the _1_ data code.
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The address/data bits of the HT12A are transmitted with a 38kHz carrier for infrared
remote controller flexibility.
The status of each address/data pin can be individually pre-set to logic _high_
or _low_. If a transmission- enable signal is applied, the encoder scans and transmits
the status of the 12 bits of address/ data serially in the order A0 to AD11 for the
HT12E encoder. During information transmission these bits are transmitted with a
preceding synchronization bit. If the trigger signal is not applied, the chip enters the
standby mode and consumes a reduced current of less than 1_A for a supply voltage
of 5V.
Usual applications preset the address pins with individual security codes using DIP
switches or PCB wiring, while the data is selected by push buttons or electronic
switches.
The following provides the address/data sequence table for various models of
the 212 series of encoders. The correct device should be selected according to the
individual address and data requirements.
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3.5 RF RECEIVER:
The 2 ^12 decoders are a series of CMOS LSIs for remote control
system applications. They are paired with Holtek_s 2 ^12 series of encoders for
proper operation, a pair of encoder/decoder with the same number of addresses and
data format should be chosen. The decoders receive serial addresses and data from a
programmed 2 ^12 series of encoders that are transmitted by a carrier using an RF or
an IR transmission medium. They compare the serial input data three times
continuously 2^12 with their local addresses. If no error or unmatched codes are
found, the input data codes are decoded and then transferred to the output pins.
The VT pin also goes high to indicate a valid transmission. The 2 ^12 series of
decoders are capable of decoding information that consist of N bits of address and
12_N bits of data. Of this series, the HT12D is arranged to provide 8 address bits and
4 data bits, and HT12F is used to decode 12 bits of address information.
Fig.14 RF Receiver
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3.5.1 Operation
The 212 series of decoders provides various combinations of addresses and data pins
in different packages so as to pair with the 2 12 series of encoders. The decoders
receive data that are transmitted by an encoder and interpret the first N bits of code
period as addresses and the last 12_N bits as data, where N is the address code
number. A signal on the DIN pin activates the oscillator which in turn decodes the
incoming address and data. The decoders will then check the received address three
times continuously. If the
received address codes all match the contents of the decoder_s local address, the
12_N bits of data are decoded to activate the output pins and the VT pin is set high to
indicate a valid transmission. This will last unless the address code is incorrect or no
signal is received. The output of the VT pin is high only when the transmission is
valid. Otherwise it is always low.
Of the 2 12 series of decoders, the HT12F has no data output pin but its VT pin can
be used as a omentary data output. The HT12D, on the other hand, provides 4 latch
type data pins whose data remain unchanged until new data are received.
3.5.3 Flowchart
The oscillator is disabled in the standby state and activated when a logic _high_ signal
applies to the DIN pin. That is to say, the DIN should be kept low if there is no signal
input.
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3.6 4:16 DECODER
IC 74154 is a 4-16 line decoder, it takes the 4 line BCD input and selects
respective output one among the 16 output lines. It is active low output IC so when
any output line is selected it is indicated by active low signal, rest of the output lines
will remain active high. This 4-line-to-16-line decoder utilizes TTL circuitry to
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decode four binary-coded inputs into one of sixteen mutually exclusive outputs when
both the strobe
inputs, G1 and G2, are low. The demultiplexing function is performed by using the 4
input lines to address the output line, passing data from one of the strobe inputs with
the other strobe input low. When either strobe input is high, all outputs are high. This
demultiplexer is ideally suited for implementing high-performance memory decoders.
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3.7 Power Supply:
For providing the operating voltage of various IC’s that is used in various circuit a
power supply which gives the voltage 5 V, 9V, 12V & variable power supply is
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designed. For that purpose we use the step down transformer 230/12V, 1A rating. A
rectifier is used for the converting a.c. supply into d.c. A bridge IC is used for that
purpose.
4. MOTOR CONTROL :
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A stepper motor is a brushless, synchronous electrical motor that can divide a full
rotation into a large number of steps, for example, 200 steps. Thus the motor can be
turned to a precise angle.
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Step Coil 4 Coil 3 Coil 2 Coil 1
When (1)D is send to the output port ,then at the input of the driver IC ULN 2003 a
data bit [ 0 0 0 1]B .similarly a required data bit obtained at the input of ULN by
sending [1,2,4,8] to the out port.& for anticlockwise rotation above data send in
reverse order.
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#include<stdio.h>
#include<conio.h>
#include<dos.h>
void main()
int b, c;
int a[4]={1,2,4,8}
while(!kbhit())
for(b=0;b<4;b++)
for(c=0;c<4;c++)
{ outport(0x378,a[c]);
Printf ("%d\n",a[c]);
delay (100);
getch();
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4.2 DC MOTOR CONTROL :
By using the SPDT relay we can control the direction of the rotation of the DC motor.
The triggering of relay controlled by the C programming through ULN2003.The
motor is connected to the common terminal of the relay. A diode is used for the
protection of the relay coil. The positive terminal of the supply is connected to the NO
of the relay.
When the [ 0 ,1]b send to the input of the ULN 2003 at the pin 1,2 resp. then
the relay 1 is getting triggered ,therefore the motor is rotating in the clockwise
direction . If the [ 1, 0] b send at input the motor is rotating in the anticlockwise
direction.
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4.2 Sample programme for clockwise & anticlockwise rotation ( When parallel
port directly connected to the ULN 2003.)
#include<stdio.h>
#include<conio.h>
#include<dos.h>
void main()
int a;
scanf(“%d”,&a);
if (a=1)
outport(0x378,0);
} .else
Outport (0x379,1);
getch();
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5. CONCLUSION
Computer-controlled stepper motors are one of the most versatile forms of positioning
systems, particularly when digitally controlled as part of a servo system. Stepper
motors are used in floppy disk drives, flatbed scanners, printers, plotters and many
more devices. Note that hard drives no longer use stepper motors to position the
read/write heads, instead utilizing a voice coil and servo feedback for head
positioning.
Stepper motors can also be used for positioning of valve pilot stages, for fluid control
systems.
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can pick, place, transport, and orient similar to a human arm, but with greater power,
precision, and repeatability.
Motor are employed in a wide assortment of applications in industry. Today
most of the applications are in manufacturing to move materials and tools of various
types..
The wireless control of motor is required when the motor is placed at the remote
locations, where it is very difficult to access the motor. By using this system we can
control the motor up to 3 h.p. When the precise rotation of stepper motor is required
then we can use stepper motor controlled through PC.
Using feedback the environment of the actual work station can be observed
over remote control section. For this purpose interfacing of digital camera with robot
is required.
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