Webcam based wireless welding machine

Submitted in partial fulfillment of the requirements for the award of degree of

BACHELOR OF TECHNOLOGY
IN
ELECTRONICS ENGINEERING

Submitted By:

Name Roll No
Name Roll No
Name Roll No
Name Roll No

ELECTRONICS ENGINEERING

College name

SUBMITTED TO: …………………………

Contents
Objective ......................................................................................................................................... 6
Introduction .................................................................................................................................... 6
Working ........................................................................................................................................... 7
Block diagram.................................................................................................................................. 7
Software used ................................................................................................................................. 9
HARDWARE USED ........................................................................................................................... 9
Atmega16 Microcontroller: ....................................................................................................... 10
Linear Power Supplies ............................................................................................................... 13
Linear Regulator Theory ........................................................................................................... 13
RFID Reader EM-18 ...................................................................... Error! Bookmark not defined.
Working of RFID ............................................................................... Error! Bookmark not defined.
WiFi Module - ESP8266 ................................................................ Error! Bookmark not defined.
.......................................................................................................... Error! Bookmark not defined.
Application .................................................................................................................................... 24
Advantage ..................................................................................................................................... 24
Disadvantage................................................................................................................................. 25
Future scope ................................................................................................................................. 25
References .................................................................................................................................... 25
DECLARATION

I hereby declare that the project report entitled “Webcam based

wireless welding machine” submitted is our original work and the
report has not formed the basis for the award of any degree, associate
ship, fellowship or any other similar title.

Signature:

Name:
CERTIFICATE

This is to certify that the project report entitled “Webcam based

wireless welding machine” is the bona fide work carried out by
students of “College Name” during the year 2016 in partial fulfillment
of the requirements for the award of the Degree of B. Tech. The
report has not formed the basis for the award previously of any degree,
diploma, associate ship, fellowship or any other similar title.

Signature of the guide:

Date:
ACKNOWLEDGEMENT

It gives me great pleasure to express my gratitude and heart full thanks

to all those who are helping me in complete this project.

I want to thank to “guide name”, who has always encouraged

and help me in making this project. In addition to this, I am grateful to
other faculties too who made me in right direction and gave me their
precious time and expert guidance whenever necessary through which I
could achieve this extent.

At last but not the least I am feeling glad to say about my family
whose wishes are always with me, without which it was not possible for
me to reach this extent.

I hope my work is praised and my efforts render fruitful result.

THANK YOU

Signature:

Name:
Objective

The objective of the project is to design and develop a Webcam based

wireless welding machine. The system will make the welding safer and
reduces the manual work, will be control using smart phone. Also
webcam/android smart phone will be used as camera to monitor the
welding machine.

Introduction

The system is deals with an innovative idea of webcam based wireless

welding machine. Welding is not an easy task so we develop wireless
welding machine. In this system an android phone is used to control the
motor and the welding machine is attached to it. We have used
atmega16 microcontroller, work as heart of the system. User have
android phone has virtual buttons on the software. When the user
press the button it will transmit a signal to microcontroller.
Microcontroller will process the data and control the motor. The
microcontroller and the android phone are connected using Bluetooth
link. A webcam/android phone is used as camera to watch the welding.
Webcam/android phone will send the video to the desktop/android
phone.
Working

1. An android phone is used to control machine.

2. Phone has software each key on software will send a different
ASCII code to the Bluetooth receiver.
3. Receiver will give this code to the microcontroller.
Microcontroller will control the motor driver according to this
code.
4. Motor driver IC will rotate the motors.
5. The welding machine is attached to the motor.
6. A webcam/phone is used to watch the welding at distant.
7. The video will display on desktop/phone to operate the welding
machine.
 Block diagram

Atmaga16

Microcontroller

L293D motor
driver IC
Bluetooth
module HC-
05

Laptop/android phone is
used to watch the welding
DC motor to control the
welding arm

Android phone is used to

control welding arm
Wireless
Webcam/android
phone will send the
video
Software used

 Programming of microcontroller in C programming language.

 AVR studio is used for compiling the code.
 DIP trace for PCB designing
 Eclipse for android software.
 .NET for desktop application.

Programming Languages Considered

 All the software developed for this project will be loaded into the
memory of the ATmega16 microcontroller.

 The language must be supported by the ATmega16 compiler

 The ATmega16 compiler supports C and Assembly

Reasons for Selection C Programming Language:

 Vast amount of online resources

 Ease of development

 Team members have experience of coding in C.

HARDWARE USED
  MICROCONTROLLER ATMEGA16
 POWER SUPPLY
 ANDROID PHONE/WEBCAM
 LAPTOP/PHONE
 DC MOTOR
 L293D MOTOR DRIVING IC
 BLUETOOTH HC-05
 WELDING MACHINE

Atmega16 Microcontroller:

Features
High-performance, Low-power AVR® 8-bit Microcontroller
Advanced RISC Architecture
131 Powerful Instructions Most Single-clock Cycle Execution
32 x 8 General Purpose Working Registers
Fully Static Operation
Up to 16 MIPS Throughput at 16 MHz
On-chip 2-cycle Multiplier
Nonvolatile Program and Data Memories
16K Bytes of In-System Self-Programmable Flash
Endurance: 10,000 Write/Erase Cycles
Optional Boot Code Section with Independent Lock Bits
In-System Programming by On-chip Boot Program
True Read-While-Write Operation
512 Bytes EEPROM
Endurance: 100,000 Write/Erase Cycles
1K Byte Internal SRAM
Programming Lock for Software Security
JTAG (IEEE std. 1149.1 Compliant) Interface
Boundary-scan Capabilities According to the JTAG Standard
Extensive On-chip Debug Support
Programming of Flash, EEPROM, Fuses, and Lock Bits through the JTAG
Interface
Peripheral Features
Two 8-bit Timer/Counters with Separate Presales and Compare Modes
One 16-bit Timer/Counter with Separate Presale, Compare Mode, and
Capture
Mode
Real Time Counter with Separate Oscillator
Four PWM Channels
8-channel, 10-bit ADC
8 Single-ended Channels
7 Differential Channels in TQFP Package Only
2 Differential Channels with Programmable Gain at 1x, 10x, or 200x
Byte-oriented Two-wire Serial Interface
Programmable Serial USART
Master/Slave SPI Serial Interface
Programmable Watchdog Timer with Separate On-chip Oscillator
On-chip Analog Comparator
Special Microcontroller Features
Power-on Reset and Programmable Brown-out Detection
Internal Calibrated RC Oscillator
External and Internal Interrupt Sources
Six Sleep Modes: Idle, ADC Noise Reduction, Power-save, Power-down,
Standby and Extended Standby
I/O and Packages
32 Programmable I/O Lines
40-pin PDIP, 44-lead TQFP, and 44-pad MLF
Operating Voltages
2.7 - 5.5V for ATmega16L
4.5 - 5.5V for ATmega16
Speed Grades
0 - 8 MHz for ATmega16L
0 - 16 MHz for ATmega16
Power Consumption @ 1 MHz, 3V, and 25°C for ATmega16L
Active: 1.1 mA
Idle Mode: 0.35 mA
Power-down Mode: < 1 μA
Linear Power Supplies

In the last installment of the Power Supply Tutorial, we found that the
most basic power supply was of a simple unregulated design. We also
found that for all but the least demanding applications, the unregulated
design is not able to maintain the output voltage close enough to the
prescribed set point as the line voltage and load current changes. Thus,
regulation methods have been developed to maintain the output
voltage or current at a constant set point. The first type of regulated
design was the linear regulator power supply.

The term “linear power supply” is typically thought of as a type of

AC/DC system, providing a regulated output. The linear regulator is
actually the part of the linear regulator power supply that performs the
regulation.

Linear Regulator Theory

Linear regulators employ a pass element serving as a variable resistor

which forms a voltage divider with the load.

The pass element functioning as a variable resistor can be

semiconductor devices such as a bipolar junction transistor (BJT),
power metal oxide semiconductor field effect transistor (MOSFET),
insulated gate bipolar transistor (IGBT), or an electron tube such as a
triode, tetrad, or pentode. Electron tubes would be used in highly
specialized applications where there are no semiconductor devices
suitable.

Power Output Capability

A linear regulator can be designed to regulate power outputs as small

as a watt or less. Linear regulators used alone in this fashion are
performing DC/DC conversion. Linear power supplies can be designed
to provide AC/DC conversion up to tens of kilowatts or even more. In
this case the linear regulator is coupled with additional circuitry
providing rectification and filtering.

Noise and Ripple

Perhaps the most significant merit of linear power supplies is the

cleanliness of the output voltage and the relative lack of
electromagnetic emissions. The typical peak to peak output voltage
ripple for a linear supply might be 1000x or 60dB less than the output
DC level. So for a 5V output supply the typical peak to peak ripple
voltage might be 5mV. A switching supply typically sees about a 100x or
40dB reduction. It is possible with careful design to achieve a 10,000x
or 80dB reduction in a linear regulated power supply.

Transient Response

The response of linear power supplies to line and load transients are
better their switching counterparts because the linear supply does not
have a switching frequency to limit the bandwidth. In linear supplies,
the regulation bandwidth is typically limited by parasitic device
elements.

Weight and Size

The weight and size of the linear power supply is the major
disadvantage. AC/DC conversion is done at low frequencies and
therefore the transformer must be large to keep the core from
saturating. This factor, along with efficiency to be discussed next, is the
main reason why linear power supplies have limited use today. For
example, a 500W linear power supply might weigh about 50 pounds
and occupy a desktop. Whereas a 500W switching supply might weight
less than 10 pounds and sits on a small part of the desktop.

Efficiency

Linear regulators are typically thought of a being extremely inefficient –

but that is not always the case and they can sometimes be more
efficient that a switching power supply!

On a first order basis, the efficiency of a linear regulator is very simple

to determine. The efficiency is simply the output voltage divided by the
input voltage. If determined effort is made to keep the difference
between the pass element input voltage and the output voltage as
small as possible, the efficiency can be very good. This type of linear
regulator is called a “low-dropout regulator”. For other cases where the
operating point is not conducive to maintaining a low dropout, the
linear regulator efficiency can suffer greatly.
As an example, if the input voltage in the figure above is 13.6 volts, and
the regulator maintains an output voltage of 12 volts, for a voltage drop
of 1.6 volts, the efficiency of the linear regulator is 12V/13.6V = 88.2%.
The efficiency in this case is very good by most standards.

As another example, if the input voltage is 5 volts and the output

voltage is 3.3 volts, for a voltage drop of 1.7 volts, the efficiency is
3.3V/5V = 66%. The efficiency in this case is not very good by most
standards.

As a last example, if the input voltage is 5 volts and the output voltage
is 1.8 volts, for a pass element voltage drop of 3.2 volts, the efficiency is
1.8V/5V = 36%. This efficiency in this case is very poor.

Summary

In this article we found that linear power supplies excel in producing

outputs with very low noise and ripple, low electromagnetic emissions,
and have excellent transient response. However, they are by nature
large and heavy when compared to switching power supplies. Linear
power supplies would be the type of choice when outputs with low
ripple and noise content are of paramount concern, and where larger
size and substantially greater weight can be tolerated.

Bluetooth Module HC-05

Bluetooth is a wireless technology standard for exchanging data over
short distances (using short-wavelength UHF radio waves in theISM
band from 2.4 to 2.485 GHz[4]) from fixed and mobile devices, and
building personal area networks (PANs). Invented by telecom
vendor Ericsson in 1994,[5] it was originally conceived as a wireless
alternative to RS-232 data cables. It can connect several devices,
overcoming problems of synchronization.
Bluetooth is managed by the Bluetooth Special Interest Group (SIG),
which has more than 25,000 member companies in the areas of
telecommunication, computing, networking, and consumer
electronics.[6] The IEEE standardized Bluetooth as IEEE 802.15.1, but no
longer maintains the standard. The Bluetooth SIG oversees
development of the specification, manages the qualification program,
and protects the trademarks.[7] A manufacturer must make a device
meet Bluetooth SIG standards to market it as a Bluetooth device.[8] A
network of patents applies to the technology, which are licensed to
individual qualifying devices.
Overview

HC-05 module is an easy to use Bluetooth SPP (Serial Port Protocol)

module, designed for transparent wireless serial connection setup.

Serial port Bluetooth module is fully qualified Bluetooth V2.0+EDR

(Enhanced Data Rate) 3Mbps Modulation with complete 2.4GHz radio
transceiver and baseband. It uses CSR Blue core 04-External single chip
Bluetooth system with CMOS technology and with AFH(Adaptive
Frequency Hopping Feature). It has the footprint as small as
12.7mmx27mm. Hope it will simplify your overall design/development
cycle.

Specifications

Hardware Features

 Typical -80dBm sensitivity

 Up to +4dBm RF transmit power
 Low Power 1.8V Operation ,1.8 to 3.6V I/O
 PIO control
 UART interface with programmable baud rate
 With integrated antenna
 With edge connector

Software Features

Default Baud rate: 38400, Data bits:8, Stop bit:1,Parity: No parity,

Data control: has.

Supported baud rate: 9600, 19200, 38400, 57600,115200,230400,and

460800.

 Given a rising pulse in PIO0, device will be disconnected.

 Status instruction port PIO1: low-disconnected, high-connected;
 PIO10 and PIO11 can be connected to red and blue led separately.
When master and slave are paired, red and blue led blinks
1time/2s in interval, while disconnected only blue led blinks
2times/s.

 Auto-connect to the last device on power as default.

 Permit pairing device to connect as default.
 Auto-pairing PINCODE:”0000” as default
 Auto-reconnect in 30 min when disconnected as a result of
beyond the range of connection.

12V gear DC motor 60RPM

 200RPM 12V DC geared motors for robotics applications

 Easy to use and available in standard size
 Nut and threads on shaft to easily connect and internal threaded
shaft for easily connecting it to wheel

Features
 200RPM 12V DC motors with Gearbox
 3000RPM base motor
 6mm shaft diameter with internal hole
 125gm weight
 Same size motor available in various rpm
 0.5kgcm torque
 No-load current = 60 mA (Max), Load current = 300 mA(Max)
A DC motor is any of a class of electrical machines that converts
direct current electrical power into mechanical power. The most
common types rely on the forces produced by magnetic fields.
Nearly all types of DC motors have some internal mechanism,
either electromechanical or electronic; to periodically change the
direction of current flow in part of the motor. Most types produce
rotary motion; a linear motor directly produces force and motion
in a straight line.

DC motors were the first type widely used, since they could be
powered from existing direct-current lighting power distribution
systems. A DC motor's speed can be controlled over a wide range,
using either a variable supply voltage or by changing the strength
of current in its field windings. Small DC motors are used in tools,
toys, and appliances. The universal motor can operate on direct
current but is a lightweight motor used for portable power tools
and appliances. Larger DC motors are used in propulsion of
electric vehicles, elevator and hoists, or in drives for steel rolling
mills. The advent of power electronics has made replacement of
DC motors with AC motors possible in many applications.
 Geared DC motors can be defined as an extension of DC motor
which already had its Insight details demystified here. A geared
DC Motor has a gear assembly attached to the motor. The speed
of motor is counted in terms of rotations of the shaft per minute
and is termed as RPM .The gear assembly helps in increasing the
torque and reducing the speed. Using the correct combination of
gears in a gear motor, its speed can be reduced to any desirable
figure. This concept where gears reduce the speed of the vehicle
but increase its torque is known as gear reduction. This Insight
will explore all the minor and major details that make the gear
head and hence the working of geared DC motor.

L293D Motor Driver IC

L293D is a dual H-bridge motor driver integrated circuit (IC). Motor

drivers act as current amplifiers since they take a low-current control
signal and provide a higher-current signal. This higher current signal is
used to drive the motors.
L293D contains two inbuilt H-bridge driver circuits. In its common mode
of operation, two DC motors can be driven simultaneously, both in
forward and reverse direction. The motor operations of two motors can
be controlled by input logic at pins 2 & 7 and 10 & 15. Input logic 00 or
11 will stop the corresponding motor. Logic 01 and 10 will rotate it in
clockwise and anticlockwise directions, respectively.
Enable pins 1 and 9 (corresponding to the two motors) must be high for
motors to start operating. When an enable input is high, the associated
driver gets enabled. As a result, the outputs become active and work in
phase with their inputs. Similarly, when the enable input is low, that
driver is disabled, and their outputs are off and in the high-impedance
Working of L293D
There are 4 input pins for l293d, pin 2,7 on the left and pin 15 ,10 on
the right as shown on the pin diagram. Left input pins will regulate the
rotation of motor connected across left side and right input for motor
on the right hand side. The motors are rotated on the basis of the
inputs provided across the input pins as LOGIC 0 or LOGIC 1.

In simple you need to provide Logic 0 or 1 across the input pins for
rotating the motor.

L293D Logic Table

Let’s consider a Motor connected on left side output pins (pin 3,6). For
rotating the motor in clockwise direction the input pins has to be
provided with Logic 1 and Logic 0.

• Pin 2 = Logic 1 and Pin 7 = Logic 0 | Clockwise Direction

• Pin 2 = Logic 0 and Pin 7 = Logic 1 | Anticlockwise Direction
• Pin 2 = Logic 0 and Pin 7 = Logic 0 | Idle [No rotation] [Hi-Impedance
state]
• Pin 2 = Logic 1 and Pin 7 = Logic 1 | Idle [No rotation]

Voltage Specification
VCC is the voltage that it needs for its own internal operation 5v; L293D
will not use this voltage for driving the motor. For driving the motors it
has a separate provision to provide motor supply VSS (V supply). L293d
will use this to drive the motor. It means if you want to operate a motor
at 9V then you need to provide a Supply of 9V across VSS Motor supply.

The maximum voltage for VSS motor supply is 36V. It can supply a max
current of 600mA per channel. Since it can drive motors Up to 36v
hence you can drive pretty big motors with this l293d.

VCC pin 16 is the voltage for its own internal Operation. The maximum
voltage ranges from 5v and up to 36v.

Application
The system can be used in mechanical industry

Can be use in railway.

Advantage
It is safe and easy method of welding.

It escapes the worker of being burn and also from harmful radiation of
welding.

It reduces the manual work makes the welding fast.

Disadvantage

The device is only prototype it will work but has limitation.

Bluetooth will not work if we work beyond the range.

Future scope

It can be modified and be used to make pick and place robot.

It can be in car drilling machine, grinding machine.

It system can be used in many engineering projects.

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