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Analysis of Factors Affecting the Rotation Speed of Axial-Flux Free-Rotor Electromagnetic Stirrer
the optimum design parameters of the electromagnetic stirrer. as steel coded AISI1030 and AISI1050 by the American Iron
and Steel Institute (AISI). 2 electromagnetic stirrers with
II. MATERIAL AND METHOD different stator cores having different magnetic permeability
are produced to enable us to see the effects of core
In the study, first of all, the cores of the electromagnetic characteristics. The chemical content of these manufactured
stirrer are defined and bought, and their lathe processes are steels is given in Table 2.1.
carried out. The cores of 2 electromagnetic stirrers are chosen
Steel Code C Si Mn P S Cr Mo Ni Al Sn Cu
AISI 1030 0.308 0.222 0.747 0.013 0.017 0.250 0.050 0.288 0.014 0.008 0.252
AISI 1050 0.492 0.221 0.718 0.011 0.010 0.149 0.054 0.125 0.021 0.012 0.261
Table 2.1: Percentages of Chemical Contents in Manufactured Steels Used for Cores
Steel samples are cut and lathed for electromagnetic Next step, 3-phase winding groups are winded around
stirrer cores with 12 cm radius (r), and 3.5 cm height. After the channels as seen in Fig. 2.1b. The number of turns of
that, 12 separate channels with 0.5 cm width and 2.5 cm each winding group is 150, and 0.5 cm diameter copper
depth are opened on the cores for windings (Fig. 2.1a). wire is used for the windings. To each winding group, 120
After lathe treatment, just before the winding process, phase delayed (regarding the previous winding group)
cores are exposed to the magnetic field for a while in order sinus voltage signals are applied. Winding groups with the
to remove the stress which may have occurred in the lathe core and the stator of the developed electromagnetic stirrer
process. can be seen in Fig.2.1c and Fig.2.1d, respectively.
(a)
(b)
(c) (d)
228 www.erpublication.org
International Journal of Engineering and Technical Research (IJETR)
ISSN: 2321-0869 (O) 2454-4698 (P), Volume-3, Issue-8, August 2015
Fig. 2.1.: (a) Treated core, (b) Winding geometry, (c) Settlement of windings in the core, (d) Stator of the developed
electromagnetic stirrer.
Designed and produced stators of electromagnetic microcontroller and L298N drivers to protect the system
stirrers with different core characteristics can be seen in against short circuit and current leakage situations. For
Fig.2.2. The core geometries of these 2 stators is supplying the power to the electromagnetic stirrer, 9V and
completely identical, while magnetic permeability 24V DC power suppliers are developed to ensure a stable
coefficients are different. Magnetic permeability voltage level which is rectified and adapted from mains
coefficient of the first electromagnetic stirrers stator core voltage. The last design step of the driver circuit is to
is 1560 (Fig.2.2a), while second electromagnetic stirrers is design and produce the front panel with 2-line LCD screen
1420 (Fig.2.2b). and keypad allowing the entering of the rpm (rotation per
minute) value and the starting and stopping of the stirring
After developing stators of the electromagnetic stirrers, process. In Fig.2.3a and Fig.2.3b, ISIS Schematic view of
the design of the electronic driver circuits has been started. the driver components and ISIS Schematic view of the
In the circuit, PIC16F876 is selected as the microprocessor related components can be seen
microprocessor, while L298N is selected as the driver IC respectively. Also, the pictures from different angles of the
(integrated circuit). For every phase, 3 ICs of L298N are all components placed in a packaging box can be seen in
responsible for driving each winding group. Thus, a current Fig.2.4a-b.
up to 3A is ensured of flowing through each winding group
without any problems. An opto-isolator is used between
(a) (b)
Fig.2.2: (a) First electromagnetic stirrers stator core (=1560), (b) Second electromagnetic stirrers stator core
(=1420).
The driver unit increases the rpm value of the magnetic microcontroller program for the driver is developed by
fish step by step within a short time until it reaches the rpm using PIC BASIC Pro compiler software. The developed
value which is defined by the user. This is because the program can be seen in Appendix-1. This program contains
magnetic fish may not follow the rotating stator if the stator mainly the current switching algorithms for every winding
starts to rotate immediately at the defined rpm value, and group, and also the codes for controlling and acquiring the
may not be able to catch the stators movements again. In information in the front panel. The experimental setup of
the course of this rpm increasing period, the LED in the the developed electromagnetic stirrers can be seen in
front panel is blinking, while it remains steadily ON after Fig.2.5 a-b.
the required rpm is reached. The PIC16F876
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Analysis of Factors Affecting the Rotation Speed of Axial-Flux Free-Rotor Electromagnetic Stirrer
VDD Vi
J1 J2 J3
PIN PIN PIN
9 4 U1
5
F1_1IN IN1 VCC VS
7 2
F1_2IN IN2 OUT1 F1_1OUT
10
IN3
12 3
IN4 OUT2 F1_2OUT
6
ENA
11 13
VDD ENB OUT3
VDD
Vi
1 14
SENSA OUT4
15
SENSB GND
J7 J8 J9 J10 J11 J12
PIN PIN PIN PIN PIN PIN 8 L298
VDD Vi
9 4
U2
F1_1IN
F1_2IN
F2_1IN
F2_2IN
F3_1IN
F3_2IN
5
F2_1IN IN1 VCC VS
7 2
F2_2IN IN2 OUT1 F2_1OUT
10
IN3
12 3
J13 J14 J15 J16 J17 J18 6
IN4 OUT2 F2_2OUT
PIN PIN PIN PIN PIN PIN ENA
11 13
VDD ENB OUT3
1 14
SENSA OUT4
15
SENSB GND
L298
8
F1_1OUT
F1_2OUT
F2_1OUT
F2_2OUT
F3_1OUT
F3_2OUT
VDD Vi
9 4
U3
5
F3_1IN IN1 VCC VS
7 2
F3_2IN IN2 OUT1 F3_1OUT
10
IN3
12 3
IN4 OUT2 F3_2OUT
6
ENA
11 13
VDD ENB OUT3
1 14
SENSA OUT4
15
SENSB GND
L298
8
(a)
4MHz
ENTER
X1
ILERI
GERI
ESC
LED
ENTER
ILERI
GERI
ESC
LED
VDD
4K7
R1
5
10
7
6
5
4
3
2
4
3
PIC16F876
U1
RA5/AN4/SS
RA4/T0CKI
RA3/AN3/VREF+
RA2/AN2/VREF-
RA1/AN1
RA0/AN0
MCLR/Vpp/THV
OSC2/CLKOUT
OSC1/CLKIN
2
220R
R3
CONN-SIL10
J3
1
D7
2
D6
3
D5
RC0/T1OSO/T1CKI
VDD 4
RC1/T1OSI/CCP2
D4
5
7
6
5
4
3
2
1
RC3/SCK/SCL
EN
RC4/SDI/SDA
TU TAKIMI
6
RC7/RX/DT
RC6/TX/CK
WR
J1
RC2/CCP1
7
RB3/PGM
RC5/SDO
RB7/PGD
RB6/PGC
RS
RB0/INT
8
VSS
9
RB5
RB4
RB2
RB1
VDD
10
VSS
1k
R2
18
17
16
15
14
13
12
11
28
27
26
25
24
23
22
21
F3_2OUT
F3_1OUT
F2_2OUT
F2_1OUT
F1_2OUT
F1_1OUT
F3_2IN_PIC
F3_1IN_PIC
F2_2IN_PIC
F2_1IN_PIC
F1_2IN_PIC
F1_1IN_PIC
D7
D6
D5
D4
EN
WR
RS
6
5
4
3
2
1
SARGILAR
J4
F1_2IN_PIC
F1_1IN_PIC
F3_2IN_PIC
F3_1IN_PIC
F2_2IN_PIC
F2_1IN_PIC
220R
R14
220R
R12
220R
R10
220R
R8
220R
R6
220R
R4
2
1
PC817
PC817
PC817
PC817
PC817
PC817
U8
U7
U6
U5
U2
U19
3
4
1k
R15
1k
R13
1k
R11
1k
R9
1k
R7
1k
R5
PWR_GND
PWR_GND
PWR_GND
PWR_GND
PWR_GND
PWR_GND
F3_2IN
F3_1IN
F2_2IN
F2_1IN
F1_2IN
F1_1IN
+5V
+5V
+5V
+5V
+5V
+5V
D10
D9
D6
D5
D2
D1
D12
D11
D8
D7
D4
D3
PWR_GND
F3_2OUT
F3_1OUT
Vi
PWR_GND
F2_2OUT
F2_1OUT
Vi
PWR_GND
F1_2OUT
F1_1OUT
Vi
L298 MODUL
M3
L298 MODUL
M2
L298 MODUL
M1
1 1 1
PW R_GND PW R_GND PW R_GND
2 2 2
+5V +5V +5V
3 3 3
Vi Vi Vi
4 4 4
F1_1IN F1_1IN F1_1IN
5 5 5
F1_2IN F1_2IN F1_2IN
6 6 6
F2_1IN F2_1IN F2_1IN
7 7 7
F2_2IN F2_2IN F2_2IN
8 8 8
F3_1IN F3_1IN F3_1IN
9 9 9
F3_2IN F3_2IN F3_2IN
10 10 10
F1_1OUT F1_1OUT F1_1OUT
11 11 11
F1_2OUT F1_2OUT F1_2OUT
12 12 12
F2_1OUT F2_1OUT F2_1OUT
13 13 13
F2_2OUT F2_2OUT F2_2OUT
14 14 14
F3_1OUT F3_1OUT F3_1OUT
15 15 15
F3_2OUT F3_2OUT F3_2OUT
MCU_PWR
POWER
POWER
J2
J6
J5
1
2
1
2
1
2
G2SB60
G2SB60
GBU6M
BR1
BR3
BR2
1000u
C3
1000u
C5
2200u
C4
1
PWR_GND
Vi
7805
U3
7805
U4
VI
VI
2 2
GND GND
VO
VO
100n
C6
100n
C8
3
3
PWR_GND
VDD
+5V
100u
C7
100u
C9
(b)
Fig. 2.3: ISIS Schematic view of the components in electronic design software- Proteus (a) driver components, (b)
microprocessor related components.
230 www.erpublication.org
International Journal of Engineering and Technical Research (IJETR)
ISSN: 2321-0869 (O) 2454-4698 (P), Volume-3, Issue-8, August 2015
(a) (b)
Fig. 2.4: Pictures from different angles of the electronic driver unit developed for driving the electromagnetic stirrers
stator (a) from the top, (b) sideward
(a)
(b)
Fig. 2.5: The experimental setup of the developed electromagnetic stirrers (a) top view, (b) front view
In the study, essentially 3 different liquids with different electromagnetic stirrers (with different stator cores) for
density and viscosity are used with both of the testing the stirring performances. For every test, rpm value
231 www.erpublication.org
Analysis of Factors Affecting the Rotation Speed of Axial-Flux Free-Rotor Electromagnetic Stirrer
As can be seen in Fig. 2.6, the parameters rx (the III. EXPERIMENTAL FINDINGS
distance between the magnetic fish and the center of the
magnetic field) B (flux density of the magnetic fish), M In the experimental phase of the study, first, the
(mass of the magnetic fish), L (length of the magnetic fish), relationship between the liquid volume and maximum
(viscosity of the liquid), Ak (sectional area of the angular velocity has been investigated. For this purpose, all
magnetic fish), A (base area of the cup) and Vc (volume of the parameters, except liquid volume, were kept constant.
the magnetic fish) dont change through the stirring For three different liquid types, measurements were started
process, so the total magnetic field (BT), liquid volume (Vs) with 250 ml and have been repeated until 4000 ml with
and the density of the liquid (s) are the parameters that 250 ml increments. Results are shown in graphics below
affect the angular speed of the magnetic fish (). (Fig.3.1a-i).
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International Journal of Engineering and Technical Research (IJETR)
ISSN: 2321-0869 (O) 2454-4698 (P), Volume-3, Issue-8, August 2015
615 600
595
610
max (rpm)
max (rpm)
590
605
585
600
580
595
575
590 570
0 500 1000 1500 2000 2500 3000 3500 4000 0 500 1000 1500 2000 2500 3000 3500 4000
Vs(ml) Vs (ml)
(a) (b)
Liquid:Water
620
610
max (rpm)
600
590
580
1. Electromagnetic Stirrer
2. Electromagnetic Stirrer
570
0 500 1000 1500 2000 2500 3000 3500 4000
Vs (ml)
(c)
1. Electromagnetic Stirrer 2. Electromagnetic Stirrer
Liquid: 10W/30 Engine Oil Liquid: 10W/30 Engine Oil
730 540
720 520
710 500
max (rpm)
max (rpm)
700 480
690 460
680 440
700
650
600
max (rpm)
550
500
450
1. Electromagnetic Stirrer
2. Electromagnetic Stirrer
400
0 500 1000 1500 2000 2500 3000 3500 4000
Vs (ml)
(f)
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Analysis of Factors Affecting the Rotation Speed of Axial-Flux Free-Rotor Electromagnetic Stirrer
230 180
220 170
max (rpm)
max (rpm)
210 160
200 150
190 140
180 130
0 500 1000 1500 2000 2500 3000 3500 4000 0 500 1000 1500 2000 2500 3000 3500 4000
Vs (ml) Vs (ml)
(g) (h)
Liquid: 20W/50 Engine Oil
240
220
200
max (rpm)
180
160
Vs (ml)
(i)
Fig. 3.1: The relationship between liquid volume and maximum angular speed (a) for water in 1 st Stirrer, (b) for water
in 2st Stirrer, (c) for water in both of Stirrers, (d) for 10W/30 engine oil in 1 st Stirrer, (e) for 10W/30 engine oil in 2 st
Stirrer, (f) for 10W/30 engine oil in both of Stirrers, (g) for 20W/50 engine oil in 1st Stirrer, (h) for 20W/50 engine oil in
2st Stirrer, (i) for 20W/50 engine oil in both of Stirrers.
In the next step of our study, the relationship between oil. The relationship is defined with constant 2000 ml
density and angular velocity is investigated using liquids liquid volume and the results are shown in the graphics
with different densities: water (1 g/ml), SAE 10W/30 below (Fig. 3.2a-b).
(0.878 g/ml) and SAE 20W/50 (0.887 g/ml) types of engine
400
max (rpm)
max (rpm)
400
300
300
200
200
100 100
(g/ml) (g/ml)
(a) (b)
Fig. 3.2: The relationship between density and angular velocity for constant liquid volume (a) 1 st electromagnetic
stirrer, (b) 2st electromagnetic stirrer.
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International Journal of Engineering and Technical Research (IJETR)
ISSN: 2321-0869 (O) 2454-4698 (P), Volume-3, Issue-8, August 2015
IV. DISCUSSION V. CONCLUSION
Fig. 3.1 demonstrates that increasing liquid volume As result of the experiments undertaken in the scope of
causes an incremental increase in the maximum angular this study, it is proven that k kinetic friction coefficient
velocity until a certain value, after which the increasing takes an active role in the variation of density and liquid
liquid volume causes the maximum angular velocity to volume with maximum angular velocity, depending on the
decrease. This phenomenon shows that the energy lost by position of the magnetic fish and surface roughness. For
friction (Ws) is decreased at first but starts increasing after example, it is stated that on the variation of maximum
a specified point. On the other hand, looking at (2) one can angular velocity and density, it is affected by not only
think that the increment on Vs should also make Fs and Ws density but by a combined effect of k and density. Also, it
increase. But with increased Vs, the magnetic fish makes is stated that the most suitable liquid for developed
contact with the cup surface and starts being exposed to a electromagnetic mixers, among the tested samples, is
different friction coefficient. Consequently, the magnetic 10W/30 engine oil. In addition, it is possible to say that
fish is exposed to a different friction after about 3000 ml. maximum angular velocity during the mixing process
As a result, we can say that the friction coefficient between depends on the geometry of the magnetic fish and on
magnetic fish and water is smaller than the friction viscosity.
coefficient between magnetic fish and cup.
235 www.erpublication.org
FAZ2_1 VAR PORTC.2 ENDIF
FAZ2_2 VAR PORTC.3 IF ENTER=1 THEN
FAZ3_1 VAR PORTC.4 PAUSE 25
FAZ3_2 VAR PORTC.5 ENTER_CEK:
DEVIR VAR WORD IF ENTER=1 THEN ENTER_CEK
DEVIRH VAR DEVIR.BYTE1 GOTO KARISTIR
DEVIRL VAR DEVIR.BYTE0 ENDIF
SAYAC VAR BYTE BAYRAK=0
BAYRAK VAR BIT SAYAC=0
I VAR BYTE GOTO BASLA_LCD
SAYICI VAR BYTE KARISTIR:
KARARLI VAR BIT LCDOUT $FE,1
INT VAR BYTE LCDOUT $FE,$80,"Haz",$AA,"rlan",$AA, "yor..."
FARK VAR BYTE WRITE 0, DEVIRH
BEKLE VAR WORD WRITE 1, DEVIRL
A VAR WORD PAUSE 1000
B VAR WORD LCDOUT $FE, 1
C VAR WORD LCDOUT $FE, $80, #DEVIR," rpm ile"
D VAR WORD LCDOUT $FE, $C0,"kar",$aa,"st",$aa,"r", $aa, "l",$aa,"yor..."
G VAR WORD GOTO HESAPLA
H VAR WORD DURDUR_BAS:
J VAR WORD IF ESC=1 THEN DURDUR
K VAR WORD GOTO DURDUR_BAS
L VAR WORD DURDUR_LCD:
E VAR WORD LCDOUT $FE, 1
F VAR WORD LCDOUT $FE, $80,"KARISTIRMA"
GECIK VAR WORD LCDOUT $FE, $C0,"DURDURULUYOR"
X VAR WORD PAUSE 1000
CALL INITIAL GOTO DURDUR
LCDOUT $FE, $80,"ELEKTROMANYETiK" '********************************
LCDOUT $FE, $C0," KARISTIRICI " HESAPLA:
READ 0, DEVIRH FARK=150
READ 1, DEVIRL A=50000/DEVIR
FOR I=0 TO 15 B=DEVIR*A
LED=1 C=50000-B
PAUSE 50 D=C*10
LED=0 E=D/DEVIR
PAUSE 50 G=E*DEVIR
NEXT I H=D-G
EN_BAS: J=H*10
LED=1 K=I/DEVIR
SAYAC=0 F=A*100
BAYRAK=0 F=F+E*10
LCDOUT $FE,1 F=F+K
LCDOUT $FE,$80,"<Devir Say", $AA, "s", $AA,"> " GECIK=F
LCDOUT $FE, $C0,"<",#DEVIR," rpm>" X=50000
BASLA_LCD: IF DEVIR>300 THEN X=25000
IF ILERI=1 THEN FARK=150
ILERI_CEK: SAYICI=0
IF BAYRAK=0 THEN KARARLI=0
PAUSE 50 FAZ1_1=1
IF ILERI=1 THEN FAZ2_2=1
SAYAC=SAYAC+1 FAZ3_1=1
IF SAYAC=75 THEN BAYRAK=1 PAUSE 1000
GOTO ILERI_CEK BASLA:
ENDIF IF ESC=1 THEN DURDUR_LCD
ENDIF FAZ3_1=0
PAUSE 50 FAZ3_2=1
DEVIR=DEVIR+1 PAUSEUS X
IF DEVIR>3000 THEN DEVIR=3000 PAUSEUS X
LCDOUT $FE, $C0,"<", #DEVIR," rpm>" FAZ2_2=0
GOTO BASLA_LCD FAZ2_1=1
ENDIF PAUSEUS X
IF GERI=1 THEN PAUSEUS X
GERI_CEK: FAZ1_1=0
IF BAYRAK=0 THEN FAZ1_2=1
PAUSE 50 PAUSEUS X
IF GERI=1 THEN PAUSEUS X
SAYAC=SAYAC+1 FAZ3_2=0
IF SAYAC=75 THEN BAYRAK=1 FAZ3_1=1
GOTO GERI_CEK PAUSEUS X
ENDIF PAUSEUS X
ENDIF FAZ2_1=0
PAUSE 50 FAZ2_2=1
DEVIR=DEVIR-1 PAUSEUS X
IF DEVIR<100 THEN DEVIR=100 PAUSEUS X
LCDOUT $FE, $C0,"<",#DEVIR," rpm>" FAZ1_2=0
GOTO BASLA_LCD FAZ1_1=1
236 www.erpublication.org
International Journal of Engineering and Technical Research (IJETR)
ISSN: 2321-0869 (O) 2454-4698 (P), Volume-3, Issue-8, August 2015
PAUSEUS X Mustafa oramk received the B.S. degrees
PAUSEUS X from the Department of Physics Education,
IF X<GECIK THEN Institute of Science, Balikesir University,
LED=1 Balikesir, Turkey, in 2012.
GOTO BASLA
ENDIF He is currently working for the Necatibey
IF INTCON.2=1 THEN Education Faculty and Physics Education
INTCON.2=0 Department, Balikesir University, Balikesir. His
TOGGLE LED research interests are magnetism and power
x=x-1 electronics.
IF X>1000 THEN X=X-1 Hakan tak received the B.S. and Ph.D.
IF X>1660 THEN X=X-1 degrees from the Department of Electric
IF X>3500 THEN X=X-1 Education, Institute of Science, Marmara
IF X>4000 THEN X=X-2 University, Istanbul, Turkey, in 1995 and 2014,
IF X>4500 THEN X=X-3 respectively.
IF X>5000 THEN X=X-4
IF X>7500 THEN X=X-5 He is currently working for the Balikesir
IF X>10000 THEN X=X-6 Vocational High School, Electric Program,
IF X>12500 THEN X=X-7 Balikesir University, Balikesir. His research
IF X>15000 THEN X=X-8 interests are magnetism and power electronics.
IF X>20000 THEN X=X-9 Osman Kalender received the B.S. and Ph.D.
IF X>30000 THEN X=X-10 degrees from the Department of Electrical
ENDIF Education, Technical Education Faculty, Gazi
GOTO BASLA University, Ankara, Turkey, in 1986 and 2005,
DURDUR: respectively.
LED=1
FAZ1_1=0 He is currently working for the Department of
FAZ1_2=0 Electrical-Electronics Engineering, Bursa
FAZ2_1=0 Orhangazi University, Bursa. His research
FAZ2_2=0 interests are generalized electrical machinery,
FAZ3_1=0 power electronics, and magnetism.
FAZ3_2=0 Emrah Yrkl received the B.S. and Ph.D.
GOTO EN_BAS degrees from the Department of
INITIAL: Electrical-Electronics Engineering, Institute of
TRISC=0 Science, Uluda University, Bursa, Turkey, in
TRISB=0 2004 and 2013, respectively.
PORTB=0
PAUSE 20 He is currently working for the Department of
LCDOUT $FE, 1 Electrical-Electronics Engineering, Bursa
TRISA=%11111110 Orhangazi University, Bursa. His research
OPTION_REG=%10000000 interests are generalized electrical machinery,
ADCON1=6 power electronics, and magnetism.
SAYICI=0 Sedat Nazlibilek received the B.S. and M.S.
KARARLI=0 degrees in electrical engineering from
FARK=150 Bosphorous University, Istanbul, Turkey, in
RETURN 1982 and 1984, respectively and the Ph.D.
degree in electrical engineering from Middle
East Technical University, Ankara, Turkey, in
1993.
Yavuz Ege received the B.S. and Ph.D. degrees
from the Department of Physics, Institute of He was with the Nanotechnology Research
Science, Balikesir University, Balikesir, Turkey, Center, Bilkent University, Ankara, as a Visiting
in 1998 and 2005, respectively. Researcher. He was the Chief of the
Communications and Electronics Systems
He is currently working for the Necatibey Branch, Turkish General Staff, Ankara, and the
Education Faculty and Physics Education National C3 Representative with NATO
Department, Balikesir University, Balikesir. His Headquarters, Brussels, Belgium, from 1997 to
research interests are solid physics, magnetism 2000. He is currently an Associate Professor
and power electronics. with the Department of Mechatronics
Murat Kabaday received the B.S. degrees Engineering, Atilim University, Ankara, where
from the Department of Physics Education, he is the Head of the Space Mechatronics
Institute of Science, Balikesir University, Research Center. His current research interests
Balikesir, Turkey, in 2015. include communications, navigation and
identification, control systems, robotics, space
He is currently working for the Necatibey systems and sensors, control systems theory,
Education Faculty and Physics Education intelligent control, mobile sensor networks,
Department, Balikesir University, Balikesir. His sensor technologies, and robotics.
research interests are magnetism and power
electronics.
237 www.erpublication.org