Electric iron with automatic power off

P.M.Abeyrathne ( 110008R )
Undergraduate of university of moratuwa

Abstract

This product is designed as a low cost device to safeguard from damages that can be occurred while using an
electrical iron.

1. Background

Electric iron is equipment that is widely used domestically and has become something extremely
important. As it is used frequently, the probability of making accidents regarding it is also increased.
Sometimes the users forget to turn it off from the power supply and hence a lot of power is wasted and at the
same time various damages could be occurred to both the iron and other stuff. Fire risk is also possible in
some cases.
In order to stop these effect modern irons comes with various features like automatic turn off. In the
market you can find those products for your need. But with the technology has developed in them the market
price also has increased to a great level. At the same time if someone willing to buy that kind of product he
has to put his conventional iron back and spent a lot of money for it and the one used early become useless.
Thats why I have introduced this special unit that can be used to give the power supply to the iron and after
some small modification the conventional iron becomes an automatic turn off iron.

2. How it works

This product comes as a separate unit that you have to give the mains power supply to it and you can
plug the iron to the unit. The special feature is there is a sensor which comes out from the unit with a
connection wire and you have to place it on the iron.
Inside of the unit there are three separate parts and two switches connected as shown in the diagram.
First you have to plug the unit to the main power supply and turn on the switch no.1 which is a bypass switch
while other one is turned off. After the iron reached to the required heat turn off the bypass switch and turn on
the switch no.2 which turns the unit in to auto control.
 In automatic control, the unit search for an output from the sensor which is placed on the iron. When there
is a movement or a vibration on the iron it sends positive voltage to the timer circuit and hence it starts
counting 30 seconds. And when done counting it again search for an output from sensor, if not, it triggers the
relay and simply turns off the power supply for the iron. For that 30 seconds power supply remains.Section
headings

3. Circuits and components

3.1. Power supply to the unit

Power supply to the timer circuit is a 12 volt DC which should be taken from the 230volts ac mains supply.
Circuit is first drawn from the software package Proteus and simulated. In order to assure that the design is
working, it is made on a proto board and tested. Then the pcb is designed through the software package and
printed it.

Fig.4 PCB Layout 1

It is small circuit made of full wave Rectifier Bridge and 7812 ic used to rectify and stable the supply. Pin
no.4 and no.5 is connected to a 15V transformer and output is taken from pin no.1 and no.2.output is a perfect
12V supply and could give enough current for the timer circuit.

3.2. 555 Timer unit

This is the circuit which takes output signal from sensor. Circuit is powered by the above 12v power supply
circuit. Power supply is given through pin no. 8 and no.1. to the pin no. 2 the trigger pin, the input signal is
given through a biased transistor. Because the trigging occurs when the the supply is cut off for a while, but
the sensor gives a pulse when there is a movement. So that a transistor has biased and output is given through
emitter and conductor. (Vce voltage) that voltage is compared with the voltage which is given to pin no.5. R1
and C2 resistor and capacitor combination gives the time value which we need to be counted. Output is given
from pin no.3 and it is given to the relay switch through a biased transistor. Operating voltage of the relay is 5
volts. If there is a back e.m.f from the relay it can damage the circuit, so that there is a D1 diode which can
stop it harming the circuit.
 Fig.5 timer sircuit diagram to PCB 1

Fig.6 Simulated Circuit diagram 1

Fig.7 PCB Layout 2

First figure shows the circuit I have used to draw the pcb and bottom is the pcb diagram. 2 nd figure is used
to analyze the circuit as pin connectors cannot be analyzed; there I have used a voltmeter to take the
measurement. And instead of the vibration sensor, I have used a pulse generator for the analyzing.
When the output is positive the relay should be triggered to close the switch of the iron. Output voltage
was enough, but the current was not enough for trigging. So that I have used a biased transistor which
increase the output current
4. Sensor

It is a vibration sensor which changes its resistance value when it senses a movement or a vibration. No
need of power supply for that

Fig.8 Vibration sensors

The sensor has a resistance value of about 10 ohms when it is kept at rest. But when it moves or vibrates
the internal resistance value increases to a higher value about 50 to kilo ohm and sometimes disconnects. This
characteristic is used for the equipment. Voltage divider is made from the sensor and a 33k resistor and the
voltage across the sensor is given to the input of 555 IC. When there is enough voltage for the IC, it triggers.

5. Expenses

Object Price (Rs.)

Relay switch 60
Transformer 200
Sensors 60
Wires and cables 100
Other circuit equipment 200
Total 620

Table 1