Universal System Black Book

7/31/2019 Universal System Black Book

1/42

UNIVERSITY OF PUNE

A PROJECT REPORT ON

UNIVERSAL SYSTEM FOR PARAMETER

MEASUREMENT & CONTROL

Submitted By

SAURABH ATHAWALEB3383010

ADITYA B MAKHIJAB3383054

Under The Guidance Of

PROF. G.B JOSHI

In Partial Fulfillment OfB.E. (Electronics& Telecommunication)

DEPARTMENT OF

ELECTRONICS & TELECOMMUNICATION ENGG.

MIT COLLEGE OF ENGINEERING

KOTHRUD, PUNE411 03820102011


2/42

Universal System For Parameter

Measurement & Control

CERTIFICATE

This is to certify that the project titled

Universal System For Parameter Measurement & Control

By:SAURABH ATHAWALEB3383010ADITYA MAKHIJAB3383054

Is a bonafide work carried out by them, under my guidance, in partial fulfillment of

the requirement for the award of Degree of Bachelor of Engineering in Electronics

& Telecommunication of University of Pune.

Prof. G. B. Joshi Prof . V.V. Shete

Guide Head,

Dept. of E&TC Dept. of E&TC

DEPARTMENT OF

ELECTRONICS & TELECOMMUNICATION ENGG.MIT COLLEGE OF ENGINEERING

KOTHRUD, PUNE411 038

20102011

The Project entitled Universal System For Parameter Measurement &

Control is approved for the degree ofBACHELOR OF ENGINEERINGE&TC ofUniversity of Pune.

Examiners: 1. ______________________________________

2. ______________________________________

Date: Place : Pune


3/42


4/42

Universal System For Parameter

Measurement & Control

INDEX

S.NO. CONTENTS PAGE1. Introduction 1

2. Abstract 2

3. Chapter 1: Literature Survey 3

4.

Chapter 2:System Description

2.1 Block diagram

2.2 Block diagram description

2.3 Components used

2.3.1 PIC microcontroller2.3.2 Op-amp op07 and op27

2.3.3 Seven segment displays

2.3.3.1 Normal Seven segment display

2.3.3.2 Seven segment displayIC

7107

2.3.4 Various Sensors those are

compatible with system

2.4 Circuit Diagram2.4.1 Amplifier section

2.4.2 Comparator section

2.4.3 PIC(16F877A) Interface

2.4.4 power supply

5

6

7

8

910

11

12

13

13

14

20

20

21

22

23

5.

Chapter 3:Manufacturing3.1 PCB Indent Layout

3.2 PCB Mask Layout

3.3 Bottom Layout

3.4 Fabrication and Manufacturing

3.5 Algorithm

Chapter 4:Testing/Results

4.1 Hardware/Software tradeoffs4.2 Result

2424

25

27

29

30

32

3233


5/42


6/42

Universal System For ParameterMeasurement & Control

MITCOE 1

INTRODUCTION

The circuit is designed for calculating the different parameters for different types

of sensors.

The device can be attached or can connected with various types of sensors like

temperature, pressure, proximity, photo sensors etc.

The system would be designed in such a way that user would be doing its

connections and making the testing circuit, by connecting amplifier block to

sensors or comparator block or filter or control block according to the requirement.

System is having the control block thus I can create a control action if required.

System also incorporates the micro-controller for any further control actions andfor display purposes.

We would need a power supply for running all these blocks efficiently.

Thus Device will have a separate power supply block for triggering of sensors and

for working of system.


7/42


MITCOE 2

ABSTRACT

The circuit is designed for calculating the different parameters for different types

of sensors.The device would consist of a universal input block to which variable types of

sensors can be attached.

At the next stage there would be a signal-processing block, which will do the

processing of the signal coming from the sensor.

Next stage there is a amplifier, comparator & filter block. This block could be used

for amplification of the signal or for filtration of the signal or for comparing signal

with some desired level.

Next is microcontroller unit that would be used for driving a particular unit or for

some counting purpose.A relay block is installed so that we can drive a device for certain condition.

Last stage is the display block unit that consists of 7-segment display, indicators,

timers and counters.

We would need a power supply for running all these blocks efficiently. Thus

Device will have a separate power supply block that would provide:

Voltage level of: 0 - 5V & 0 - 10V Current of: 5 - 20mA & Clock pulse.

OUR AIM

Our aim is to make a device, to which various types of sensors can be connected

for which the device will calculate the different parameters. Thus in practices we

can create any circuit for testing in no time and the parameters can be observed

easily.


8/42


MITCOE 3

Chapter 1:

Literature Survey

In present world there is no system similar to that of our system. There are few

systems for measuring parameters but they cannot produce the control action,

where as our system can, and also the system can read, control and display the

parameters of various sensors, where as the present day systems can work with

only one.

The basic need of our system arises in big industries and educational institutions.

Where the system is used either for testing (in industries) or for teaching andlearning parameters (in institutions).

In educational institutions the system can be used for learning and performing

various experiments on the sensors. The student can attach any sensor and can test

its behavior, its output, its parameters etc.

Gary Stringham & Associates believe that engineering is lot about self learning

through experiments, you need to buy a development board or system and play

with it, configure it, and get the results.

Our system provides all these amenities.

In Industries also different systems are required for testing different components,

but this can be resolved by using only one system as all the testing can be

performed over one. As number of systems increases the working person is

required to learn all of them and it becomes complicated. Where as in our system

any circuit can be designed easily in no time and can be operated easily.

Some similar systems are:MULTI-PARAMETER MEASUREMENT SYSTEM:


9/42


MITCOE 4


10/42


MITCOE 5

Chapter 2:

System Description

2.1 Block Diagram:


11/42


MITCOE 6

2.2 Block Diagram Description:

The system basically would somewhat look like this:

We can create the testing circuit for any type of sensor in no time.

For example if we want to use temperature sensor and create the testing

circuit or wanting to read its parameters then the sensor can be connected at

the universal input port.

Then the power supply block will supply the power for triggering the sensor

and for other blocks.

AMPLIF

IER FILTER

RELAY

CONTR

OLCOMPAR

ATOR

DISPLA

Y

POWER SUPPLY BLOCK

I/P

BLOC


12/42


MITCOE 7

Then as the signal from the temperature sensor would be weak so we would

need an amplifier block to amplify it so we can connect its output terminals

to the amplifier block.

Then if we want to display the particular parameter of the sensor we can use

the filer and display block i.e. seven-segment display for it.

Or if we want to produce a control action we can connect the output from

amplifier to the comparator block where it will compare the signal with

some reference signal and will give the required signal at output, then the

signal can be given to relay control where the control action can take place

using a relay.

In such a way we can use any block according to our requirement and

produce any type of circuit in no time.

Main Blocks With Description

A.Universal Input Block.B.Amplifier Block.C.Filter & Display Block.D.Comparator Block.E. Relay Control Block.F. Power Supply Block.

A.Universal Input Block:

This block is used for connecting sensors from exterior world to the system.

It is the simple strip over which the sensor is connected.

B.Amplifier Block:

The block is made up of instrumentation amplifier or two stage amplifier of

op-amp. The block is used for amplification of the signal at the input and

gives the amplified signal out.


13/42


MITCOE 8

C.Filter & Display Block:

This block is used and designed to filter the signal and to display the

parameter measured for the sensor.

D.Comparator Block:

This block is used for producing the control action by comparing the signal

from the sensor with some reference signal level.

E.Relay Control Block:

The Control block is used for producing the physical action from the signal

at the input. It consists of a relay that clips on/off according to the signal

from the comparator block.

F. Power Supply Block:

The block is used for supplying the power to all the blocks and also for

triggering the sensors at universal the input block.

Block would produce the supply of :+/-5V; +/-12V.

Thus the system can be configured according to the users requirements. The usercan use only the block that is required or wants to use.

2.3 Components Used:The components used in the system are as follows:

I. Pic Microcontroller (16F877A).II. Op-amp (OP07, OP27).

III. Seven Segment Display Unit (7107).IV. Various sensors those are compatible to system.

a. Temperature Sensor.


14/42


MITCOE 9

b. Pressure Sensor.c. Proximity Switches.d. RPM or Rotation Sensors.e. Flow Sensors.

2.3.1 PIC MICROCONTROLLER:

a) Probably the most important part on the receiver side.b) Processing of the received data, driving of the LCDs, storage of old, data,

etc. functions.

c) Available options are PIC16F877A/ PIC16F874A.PIC MICROCONTROLLERS PIN DIAGRAM:


15/42


MITCOE 10

PIC16F877A Description:a) It is a 40 pin PDIP IC.b) Has the feature of parallel and serial communication.c) 4 I/O ports and 15 interrupts.d) The RAX pins are the digital I/O pins

PIC16F877A Features:a) Low-power, high-speed Flash/EEPROM.b) Technology.c) Wide operating voltage range (2.0V to 5.5V).d) Commercial & Industrial temperature ranges.e) Low-power consumption.f) 10-bit, up to 8-channel ADC.g) Brown-out Reset (BOR).h) Only 35 single-word instructions.i) All single-cycle instructions except for program branches, which are

two-cycle.

2.3.2 OP-AMP OP07 & OP27:

OP07-Features:

Low VOS: 75 _V Max. Low VOS Drift: 1.3 _V/_C Max. Ultra-Stable vs. Time: 1.5 _V/Month Max. Low Noise: 0.6 _V p-p Max.


16/42


MITCOE 11

Wide Input Voltage Range: _14 V. Wide Supply Voltage Range: 3 V to 18 V. Fits 725,108A/308A, 741, AD510 Sockets 125_C Temperature-

Tested Dice

OP07-Discription:

obtained by trimming at the wafer stage.

These low offset voltages generally eliminate any need for external nulling.

The OP07 also features low input bias current (4 nA forOP07E) and high open-loop gain (200 V/mV for OP07E).

The low offsets and high open-loop gain make the OP07 particularlyuseful for

high-gain instrumentation applications.

OP27-Features:

Low Noise: 80 nV p-p (0.1 Hz to 10 Hz), 3 nV/ Hz Low Drift: 0.2 _V/_C High Speed: 2.8 V/_s Slew Rate, 8 MHz Gain Bandwidth Low VOS: 10 _V Excellent CMRR: 126 dB at VCM of 11 V High Open-Loop Gain: 1.8 Million Fits 725, OP07, 5534A Sockets Available in Die Form


17/42


18/42


MITCOE 13

2.3.3.1 Normal Seven Segment Display:

This display will be directly interfaced with the pic microcontroller and thus

will be used by pic to display the parameters given to it.This display is a normal combination of 4 seven segments which will be

displaying the value through pic microcontroller.

2.3.3.2 Seven segment display IC 7107:

7107-Features: Guaranteed Zero Reading for 0V Input on All Scales

True Polarity at Zero for Precise Null Detection

1pA Typical Input Current True Differential Input and Reference, Direct Display Drive- LCD ICL7106, LED lCL7107

Low Noise - Less Than 15VP-P

On Chip Clock and Reference

Low Power Dissipation - Typically Less Than 10mW

No Additional Active Circuits Required

Enhanced Display Stability

Pb-Free Plus Anneal Available (RoHS Compliant)

7107-Discription:

3,1/2 Digit, LCD/LED Display, A/D Converters.

The Intersil ICL7106 and ICL7107 are high performance, low power, 3,1/2 digit

A/D converters. Included are seven segment decoders, display drivers, a reference,

and a clock.

The ICL7106 is designed to interface with a liquid crystal display (LCD) and

includes a multiplexed backplane drive; the ICL7107 will directly drive aninstrument size light emitting diode (LED) display.

The ICL7106 and ICL7107 bring together a combination of high accuracy,

versatility, and true economy. It features auto zero to less than 10V, zero drift ofless than 1V/oC, input bias current of 10pA (Max), and rollover error of less thanone count. True differential inputs and reference are useful in all systems, but give


19/42


20/42


MITCOE 15

V. The output voltage range makes the sensor particularly suitable for the 3-GHz

DSP's core voltage requirements.

The module incorporates a comprehensive list of features. Output over-current and

over-temperature shutdown protects against most load faults. A differential remote

sense ensures tight load regulation. An adjustable under-voltage lockout allows the

turn-on voltage threshold to be customized.

Auto-Tracksequencing is a popular feature that greatly simplifies thesimultaneous power-up and power-down of multiple modules in a power system

Features of temperature sensor:

Up to 10-A Output Current. 2.2-V to 5.5-V Input Voltage. Designed to meet Ultra-Fast Transient. Wide-Output Voltage Adjust (0.69 V to 2.0 V)

Requirements for 3-GHz DSP Systems.

1.5% Total Output Voltage Variation. Efficiencies up to 94% (CO = 2000 F, I = 3 A). Output Overcurrent Protection (Nonlatching, Auto-Reset)

Wireless Infrastructure Base Stations.

Operating Temperature:40C to 85C. Safety Agency Approvals: UL/IEC/CSA-C22.2 60950-1. On/Off Inhibit. Differential Output Voltage Remote Sense.

b.)Pressure Sensors:

The MPX2010/MPXV2010G series silicon piezoresistive pressure sensors provide

a very accurate and linear voltage output directly proportional to the applied

pressure. These sensors house a single monolithic silicon die with the strain gauge

and thinfilm resistor network integrated on each chip. The sensor is laser trimmed

for precise span, offset calibration and temperature compensation.

Features

Temperature Compensated over 0C to +85C

Ratiometric to Supply Voltage

Differential and Gauge Options

Application Examples


21/42


MITCOE 16

Respiratory Diagnostics

Air Movement Control

Controllers

Pressure Switching

c.) Proximity Switches:

Inductive proximityswitches being contact fewer sensors can be used for

position sensing, counting and speed measurement. They can be used in extreme

conditions, such as dusty, oily and corrosive environment. Inductive proximity

switches are used in all areas of control and automotive technology.

Specifications:

Supply voltage: 10 -30 vdc Output: PNP / NPN

Maximum load current: 300 mA

Environmental protection: IP 67 Reverse polarity protection:

Provided Short circuit protection: provided Status Indication: Through LED Sizes available: M 8, M 12, M 18, M 25,

M 30

AC Proximity Switches:

Specifications:

Supply voltage: 90 - 230 vac Output logic: NO /NC

Environmental protection: IP 67

Status Indication: Through LED Sizes available: M 12,M 18, M 30

Capacitive Proximity Switches:Capacitive proximity switches are non contact sensing solution to metallic as

well as non -metallic object. Capacitive proximity switch is a solid-state device tosense position or level of any material like Plastic, Glass, Ceramic, Wood, Leather,

Oil, Diesel, Water & Metal. They are used for Position Sensing of Plastic Pouches,

Tablets, Bottles etc. counting number of Boxes, Caps, Bottles etc. for Level

Sensing: Solid, Liquid, Flour, Powder,etc.

Specifications:


22/42


MITCOE 17

Supply voltage: 10 - 30 vdc Output: PNP / NPN

Reverse polarity protection: Provided

Short circuit protection: provided

Switching frequency: 25 Hz

Status Indication: Through LED Sizes available: M 18, M 30

d.) RPM sensors:

Features:

Self-powered operation. Direct conversion of actuator speed to output frequency. Simple installation. No moving parts. Designed for use over a wide range of speeds. Adaptable to a wide variety of configurations. Customized VRS products for unique speed sensing applications. Housing diameters: 5/8 in (M16), 3/8 in (M12), 1/4 in (8M). Housing material/style: stainless steel threaded. Terminations: MS3106 connector, preleaded. Output voltages: 4.7 Vp-p to 125 Vp-p.

Potential Applications: Engine RPM (revolutions per minute) measurement on aircraft, automobiles,

boats, buses, trucks and rail vehicles.

Motor RPM measurement on drills, grinders, lathes and automatic screwmachines.

Motor RPM measurement on precision camera, tape recording and motionpicture equipment.

Process speed measurement on food, textile, paper, woodworking, printing,tobacco and pharmaceutical industry machinery.

Motor speed measurement of electrical generating equipment. Speed measurement of pumps, blowers, mixers, exhaust and ventilating fans

Flow measurement on turbine meters.

Wheel-slip measurement on autos and locomotives Gear speedmeasurement.


23/42


MITCOE 18

e.) Flow Sensor:The flow sensors most commonly chosen for use with a PLC are EX series and TX

series insertion flow sensors. These flow sensors, which have three wires, use

Hall-effect technology. They need 5-24 Volts DC and up to 8 mA current, and

they are current sinking (NPN) devices. The flow sensors can connect directly to

the PLC if:

The flow sensor power on the PLC is 5 - 24 VDC (VDC is typical.) The flow sensor power supply can provide at least 6 mA (100 mA is

typical.)

The flow sensor input on the PLC can accept a current sinking device.If the PLC input only accepts current sourcing devices, a pull-up resistor must be

added to allow the flow sensor to work correctly. Connection of this resistor is

shown below. Typically, on a 24 VDC input a 2.2 K Ohm resistor will beeffective.

Since the three-wire, Hall-effect flow sensors are solid

state, they do not exhibit switch bounce and can be used

at relatively high frequencies. Any input module will

have certain frequency limitations, and the table on the

right gives maximum frequency that a particular flow

sensor or meter could be expected to produce.

If the PLC is equipped with a 4-20 mA analog input module, it is necessary to

order the flow sensor with some form of 4-20 mA transmitter. Two options are the

AO55 blind transmitter and FT420 flow sensor computer. Follow the connectiondiagrams for these products to connect the flow sensor output to the analog input.
http://www.globalw.com/products/EX80.htmlhttp://www.globalw.com/products/TX80.htmlhttp://www.globalw.com/products/TX80.htmlhttp://www.globalw.com/products/TX80.htmlhttp://www.globalw.com/products/TX80.htmlhttp://www.globalw.com/products/EX80.html


24/42


MITCOE 19

Connection diagram of the flow sensor:


25/42


MITCOE 20

2.4 CIRCUIT DIAGRAM

2.4.1 Amplifier Section:

Amplifier part2:


26/42


MITCOE 21

2.4.2 Comparator Section:


27/42


MITCOE 22

2.4.3 PIC (16F877A) Interface:


28/42


MITCOE 23

2.4.4 Power Supply:


29/42


MITCOE 24

Chapter 3:Manufacturing

3.1 PCB Indent Layout:

Amplifier:

COMPARATOR


30/42


MITCOE 25

Power supply:

3.2 PCB Mask Layout:

Amplifier:


31/42


MITCOE 26

Comparator:

Power supply:


32/42


33/42


MITCOE 28

Power supply:


34/42


35/42


MITCOE 30

3.5 ALGORITHM

Step 1: START

Step 2: Initialize all ports.

Step 3: Make pins RA0-RA5 as input pins.

Step 4: Continuously check for any signal changes on RA0-RA5.

Step 5: If signal changes at RA0 then count the pulses fed at_______

Step 6: If signal goes low to high then increment the count.

Step 7: Display the count.

Step 8: Keep counting till power is ON.

Step 9: Else if signal comes at RA1 then start the internal timer (with the resolution equal to

1sec.).

Step 10: Display the time.

Step 11: Stop the timer as soon as a low to high pulse is detected at RA1.

Step 12: All other pins (RA2-RA5) can be used for variety of applications (right now they are

reserved for future improvements).

Step 13: STOP.


36/42


MITCOE 31

Chapter 4:Testing/Results

a. Hardware Tradeoff:

The major problems that we faced during hardware designing were

how we will make all the sensors available in market compatible to the kit. We had to

conceder all the parameters for various sensors, so finally we came out with the

conclusion that we will make user only to make the changes with the gains and

reference voltages etc. according to the component and requirement.

b. Software Tradeoff:

The major problem faced during programming was in which languagewe should write the program weather we should write the program in assembly

language or in C language. But then we finally decided to write the programming

in C language as it was already difficult to write program in PIC and then assembly

language programming was getting more tedious.

c. Result:

The most frequent problem that we faced during the project completion was

in selection of components and calculating the values for them. After the final

completion at the while of testing we didnt faced any big problems except fromsmall errors in connections.


37/42


MITCOE 32

Chapter 5:

5.1 Applications and Scope:

The system is a universal system thus its individual block can be used in a

tandem and various results can be achieved.

System can be used in educational institution for letting students practicing on

various sensors and check there working as the testing circuit can be made in no

time.

System can test and read various parameters according to requirement of

sensors.

The system can also be used in industries for testing before installation where

sensors are used and installed in various devices.


38/42


MITCOE 33

5.2 Components list:

PARTS QUANTITY COST

PIC 16F877A 1 Rs. 250

TRANSFORMERS 3 Rs. 650

ULN2003 1 Rs.20

LM339 1 Rs.20

DISPLAY 7107 1 Rs.150

40106 2 Rs.25

78XX & 79XX 6 Rs.45

LM1458 4 Rs.25

Discrete components

-

Rs.1100

PCB Manufacturing 6 Rs.3200

TOTAL Rs.5485/-


39/42


MITCOE 34

5.3 CONCLUSION

The system has two areas for utilization:

I. One it would reduce the efforts of a teacher and students will learn andremember things easily

II. On the other hand the system when used in industries can be fruitful as onlyone system would b required for testing various sensors & it can be used

easily.

Following are the advantages of the system:

Possible to test various sensors on the same system. Testing of sensors is easy. Parameters can be calculated in no time for various sensors. System has advance feature of producing control action for some required

cases.


40/42


MITCOE 35

5.4 BIBLIOGRAPHY

References:

Internet Links:

http://www.microchip.com/downloads/en/devicedoc/30292c.pdf

http://www.pcb.com/spec_sheet.asp

http://www.omron.com

http://www.motorola.com/semiconductors/

Books:PIC microcontroller by Predco

Analog integrated circuit by Ramakant Gaikwad
http://www.pcb.com/spec_sheet.asphttp://www.omron.com/http://www.motorola.com/semiconductors/http://www.motorola.com/semiconductors/http://www.omron.com/http://www.pcb.com/spec_sheet.asp


41/42


MITCOE 36

5.5DATASHEETS


42/42

Documents

Universal System Black Book