Upload
triloksawant
View
153
Download
6
Embed Size (px)
Citation preview
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 1
PLAN OF WORK
Weekly work
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
11 WEEKLY WORK
1st week Project Name selection
1st week Literature Survey
1st week Problem Definition
2nd week Block diagram
3rd to 5th week Details of individual block
6th week Rough circuit diagram
7th week Availability of parts in market
8th week Purchasing parts
8th week Testing individual Parts
8th week Finalizing circuit diagram
9th week PCB designing
9th amp10th week Soldering of parts
11th week Testing amp troubleshooting each module
12th week Complete testing of final circuit
13th week Writing individual module of software
14th amp15th week Final testing of software module
16th week Final testing of hardware amp software
17th week Finishing final project
17th amp18th week Report preparation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 2
Table 11 Table for Weekly work
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 2
INTRODUCTION
Introduction Functional descriptionTechnology used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
21 Introduction
With mobile phones becoming the major source of businesspersonal
communication the mobile phone business is currently worth billions of dollars and
supports millions of phones
The need to provide a public charging service is essential Many critics argued that a
public mobile phone charging service is not a lucrative business because most users can
charge their phones at home in their office or in their cars
Emergency Coin Operated Mobile Phone Charger is a new business milestone
because many are attending business conventions and forgetting their charger at home or in
hotel rooms
Students and many that use the public transportation that dont know that their level
of their battery is low are prospective customers for coin operated mobile phone charger
service
Recommended locations include Hotels conference centers exhibition halls
serviced offices exchange halls motels leisure centers health clubs training centers golf
clubs retail outlets shopping malls Internet cafes universities colleges hall of residence
airports train terminals etc so that the mobile phone users can reactivate a low or dead
battery by simply plugging in and charging for as low as one rupees
22 Functional description
The coin operated public cell phone charger is a cell phone charging station having
four charging channels providing charging facility to various type of cell phones The
number of channels can be increased further Each channel can be operated simultaneously
Each and every channel is having a select switch which can be called as channel
select switch with a red LED as an indicator for selected channel Also there is a START
switch and a COIN inlet which is common for all the channels
The operation of coin operated chargers is very simple The user who wishes to
charge his cell phone has to first check out for the compatible charger jack in a channel
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 4
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Then he has to press select switch in order to make channel ready for charging the
selected channel will be indicated by a red LED
The channel will remain in selected mode for 30 sec Hence within 30 sec the user
has to first insert the predefined rupee coin and then has to press START switch which will
finally start the charging process for a predefined time and is indicated by a green LED
If failing to do so within 1 min will reset the channel and the user has to again
follow the same procedure
Any other channel selection is not considered within 30 sec of previous channel if
selected or until it has entered in to charging mode
Completion of charging will be indicated by an OFF green LED
23 Technology Used
Coin recognition using proximity switch(metal detector)
Constant voltage charger
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 3
DEVELOPMENT
STAGES amp
PROCESS
Development stages and process of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
31 DEVELOPMENT STAGES amp PROCESS
The complete development of this project can be divided into the following stages
Problem definition stage
Designing block diagram
Implementing circuits and components
Developing algorithm for software
Writing actual code for Microcontroller
Compiling the code
Burning the hex file into microcontroller with programmer
Testing and Running
311 Problem definition stage
This is the very first stage to develop any project It actually defines the aim
and the concept of the project At inconvenient times when access to a standard
charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is
designed to solve this problem The charger operates like a vending machine all a
user has to do is plug the mobile phone into one of the four adapters and insert a
coin the phone will then be given a micro-pulse fast charge in just 10 minutes
312 Designing block diagram
At this stage we have categorized the whole system into different individual
modules These modules (block diagrams) will be helpful in understanding the
concept and working of the integrated system It also simplifies the entire debugging
and testing process
313 Implementing circuits and components
This is the actual implementation of circuit of each block At this stage we
have actually designed each block separately and finally integrated them into the
complete working system
314 Developing for software
To get the logical flow of the software the development of algorithm having
a prominent role So that we have to analyze the complete system and organized the
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
algorithm in such a manner that one can understand the complete working of the
software
315 Writing actual code for Microcontroller
After the development of the algorithm and flowchart we have actually
translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so
that it can understand the instructions and run as per our requirement The
instructions are in ANSII C Language
316 Compiling the code
The hand written code on paper was then transferred into computer For that
we have used Keil pre-install on PC The Keil is a Computer Aided Program to
simulate the working of Microcontroller in real time without burning the software
into actual IC We simulated and compiled our program for error checking After
removing several compiling errors the program was converted into machine language
ie Philips hex format
317 Burning the hex file into microcontroller with Programmer
In this stage the compiled hex format file was downloaded or burned into
flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-
system programming software provided by the manufacturer itself
318 Testing and Running
This time we tested our project for actual working after loading the Software
into the microcontroller Any errors found were removed successfully This is the last
and final stage of development of our project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 4
BLOCK DIAGRAM
OF THE PROJECT
Block Diagram Brief Explanation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
11 WEEKLY WORK
1st week Project Name selection
1st week Literature Survey
1st week Problem Definition
2nd week Block diagram
3rd to 5th week Details of individual block
6th week Rough circuit diagram
7th week Availability of parts in market
8th week Purchasing parts
8th week Testing individual Parts
8th week Finalizing circuit diagram
9th week PCB designing
9th amp10th week Soldering of parts
11th week Testing amp troubleshooting each module
12th week Complete testing of final circuit
13th week Writing individual module of software
14th amp15th week Final testing of software module
16th week Final testing of hardware amp software
17th week Finishing final project
17th amp18th week Report preparation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 2
Table 11 Table for Weekly work
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 2
INTRODUCTION
Introduction Functional descriptionTechnology used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
21 Introduction
With mobile phones becoming the major source of businesspersonal
communication the mobile phone business is currently worth billions of dollars and
supports millions of phones
The need to provide a public charging service is essential Many critics argued that a
public mobile phone charging service is not a lucrative business because most users can
charge their phones at home in their office or in their cars
Emergency Coin Operated Mobile Phone Charger is a new business milestone
because many are attending business conventions and forgetting their charger at home or in
hotel rooms
Students and many that use the public transportation that dont know that their level
of their battery is low are prospective customers for coin operated mobile phone charger
service
Recommended locations include Hotels conference centers exhibition halls
serviced offices exchange halls motels leisure centers health clubs training centers golf
clubs retail outlets shopping malls Internet cafes universities colleges hall of residence
airports train terminals etc so that the mobile phone users can reactivate a low or dead
battery by simply plugging in and charging for as low as one rupees
22 Functional description
The coin operated public cell phone charger is a cell phone charging station having
four charging channels providing charging facility to various type of cell phones The
number of channels can be increased further Each channel can be operated simultaneously
Each and every channel is having a select switch which can be called as channel
select switch with a red LED as an indicator for selected channel Also there is a START
switch and a COIN inlet which is common for all the channels
The operation of coin operated chargers is very simple The user who wishes to
charge his cell phone has to first check out for the compatible charger jack in a channel
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 4
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Then he has to press select switch in order to make channel ready for charging the
selected channel will be indicated by a red LED
The channel will remain in selected mode for 30 sec Hence within 30 sec the user
has to first insert the predefined rupee coin and then has to press START switch which will
finally start the charging process for a predefined time and is indicated by a green LED
If failing to do so within 1 min will reset the channel and the user has to again
follow the same procedure
Any other channel selection is not considered within 30 sec of previous channel if
selected or until it has entered in to charging mode
Completion of charging will be indicated by an OFF green LED
23 Technology Used
Coin recognition using proximity switch(metal detector)
Constant voltage charger
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 3
DEVELOPMENT
STAGES amp
PROCESS
Development stages and process of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
31 DEVELOPMENT STAGES amp PROCESS
The complete development of this project can be divided into the following stages
Problem definition stage
Designing block diagram
Implementing circuits and components
Developing algorithm for software
Writing actual code for Microcontroller
Compiling the code
Burning the hex file into microcontroller with programmer
Testing and Running
311 Problem definition stage
This is the very first stage to develop any project It actually defines the aim
and the concept of the project At inconvenient times when access to a standard
charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is
designed to solve this problem The charger operates like a vending machine all a
user has to do is plug the mobile phone into one of the four adapters and insert a
coin the phone will then be given a micro-pulse fast charge in just 10 minutes
312 Designing block diagram
At this stage we have categorized the whole system into different individual
modules These modules (block diagrams) will be helpful in understanding the
concept and working of the integrated system It also simplifies the entire debugging
and testing process
313 Implementing circuits and components
This is the actual implementation of circuit of each block At this stage we
have actually designed each block separately and finally integrated them into the
complete working system
314 Developing for software
To get the logical flow of the software the development of algorithm having
a prominent role So that we have to analyze the complete system and organized the
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
algorithm in such a manner that one can understand the complete working of the
software
315 Writing actual code for Microcontroller
After the development of the algorithm and flowchart we have actually
translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so
that it can understand the instructions and run as per our requirement The
instructions are in ANSII C Language
316 Compiling the code
The hand written code on paper was then transferred into computer For that
we have used Keil pre-install on PC The Keil is a Computer Aided Program to
simulate the working of Microcontroller in real time without burning the software
into actual IC We simulated and compiled our program for error checking After
removing several compiling errors the program was converted into machine language
ie Philips hex format
317 Burning the hex file into microcontroller with Programmer
In this stage the compiled hex format file was downloaded or burned into
flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-
system programming software provided by the manufacturer itself
318 Testing and Running
This time we tested our project for actual working after loading the Software
into the microcontroller Any errors found were removed successfully This is the last
and final stage of development of our project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 4
BLOCK DIAGRAM
OF THE PROJECT
Block Diagram Brief Explanation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 2
INTRODUCTION
Introduction Functional descriptionTechnology used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
21 Introduction
With mobile phones becoming the major source of businesspersonal
communication the mobile phone business is currently worth billions of dollars and
supports millions of phones
The need to provide a public charging service is essential Many critics argued that a
public mobile phone charging service is not a lucrative business because most users can
charge their phones at home in their office or in their cars
Emergency Coin Operated Mobile Phone Charger is a new business milestone
because many are attending business conventions and forgetting their charger at home or in
hotel rooms
Students and many that use the public transportation that dont know that their level
of their battery is low are prospective customers for coin operated mobile phone charger
service
Recommended locations include Hotels conference centers exhibition halls
serviced offices exchange halls motels leisure centers health clubs training centers golf
clubs retail outlets shopping malls Internet cafes universities colleges hall of residence
airports train terminals etc so that the mobile phone users can reactivate a low or dead
battery by simply plugging in and charging for as low as one rupees
22 Functional description
The coin operated public cell phone charger is a cell phone charging station having
four charging channels providing charging facility to various type of cell phones The
number of channels can be increased further Each channel can be operated simultaneously
Each and every channel is having a select switch which can be called as channel
select switch with a red LED as an indicator for selected channel Also there is a START
switch and a COIN inlet which is common for all the channels
The operation of coin operated chargers is very simple The user who wishes to
charge his cell phone has to first check out for the compatible charger jack in a channel
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 4
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Then he has to press select switch in order to make channel ready for charging the
selected channel will be indicated by a red LED
The channel will remain in selected mode for 30 sec Hence within 30 sec the user
has to first insert the predefined rupee coin and then has to press START switch which will
finally start the charging process for a predefined time and is indicated by a green LED
If failing to do so within 1 min will reset the channel and the user has to again
follow the same procedure
Any other channel selection is not considered within 30 sec of previous channel if
selected or until it has entered in to charging mode
Completion of charging will be indicated by an OFF green LED
23 Technology Used
Coin recognition using proximity switch(metal detector)
Constant voltage charger
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 3
DEVELOPMENT
STAGES amp
PROCESS
Development stages and process of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
31 DEVELOPMENT STAGES amp PROCESS
The complete development of this project can be divided into the following stages
Problem definition stage
Designing block diagram
Implementing circuits and components
Developing algorithm for software
Writing actual code for Microcontroller
Compiling the code
Burning the hex file into microcontroller with programmer
Testing and Running
311 Problem definition stage
This is the very first stage to develop any project It actually defines the aim
and the concept of the project At inconvenient times when access to a standard
charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is
designed to solve this problem The charger operates like a vending machine all a
user has to do is plug the mobile phone into one of the four adapters and insert a
coin the phone will then be given a micro-pulse fast charge in just 10 minutes
312 Designing block diagram
At this stage we have categorized the whole system into different individual
modules These modules (block diagrams) will be helpful in understanding the
concept and working of the integrated system It also simplifies the entire debugging
and testing process
313 Implementing circuits and components
This is the actual implementation of circuit of each block At this stage we
have actually designed each block separately and finally integrated them into the
complete working system
314 Developing for software
To get the logical flow of the software the development of algorithm having
a prominent role So that we have to analyze the complete system and organized the
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
algorithm in such a manner that one can understand the complete working of the
software
315 Writing actual code for Microcontroller
After the development of the algorithm and flowchart we have actually
translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so
that it can understand the instructions and run as per our requirement The
instructions are in ANSII C Language
316 Compiling the code
The hand written code on paper was then transferred into computer For that
we have used Keil pre-install on PC The Keil is a Computer Aided Program to
simulate the working of Microcontroller in real time without burning the software
into actual IC We simulated and compiled our program for error checking After
removing several compiling errors the program was converted into machine language
ie Philips hex format
317 Burning the hex file into microcontroller with Programmer
In this stage the compiled hex format file was downloaded or burned into
flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-
system programming software provided by the manufacturer itself
318 Testing and Running
This time we tested our project for actual working after loading the Software
into the microcontroller Any errors found were removed successfully This is the last
and final stage of development of our project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 4
BLOCK DIAGRAM
OF THE PROJECT
Block Diagram Brief Explanation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
21 Introduction
With mobile phones becoming the major source of businesspersonal
communication the mobile phone business is currently worth billions of dollars and
supports millions of phones
The need to provide a public charging service is essential Many critics argued that a
public mobile phone charging service is not a lucrative business because most users can
charge their phones at home in their office or in their cars
Emergency Coin Operated Mobile Phone Charger is a new business milestone
because many are attending business conventions and forgetting their charger at home or in
hotel rooms
Students and many that use the public transportation that dont know that their level
of their battery is low are prospective customers for coin operated mobile phone charger
service
Recommended locations include Hotels conference centers exhibition halls
serviced offices exchange halls motels leisure centers health clubs training centers golf
clubs retail outlets shopping malls Internet cafes universities colleges hall of residence
airports train terminals etc so that the mobile phone users can reactivate a low or dead
battery by simply plugging in and charging for as low as one rupees
22 Functional description
The coin operated public cell phone charger is a cell phone charging station having
four charging channels providing charging facility to various type of cell phones The
number of channels can be increased further Each channel can be operated simultaneously
Each and every channel is having a select switch which can be called as channel
select switch with a red LED as an indicator for selected channel Also there is a START
switch and a COIN inlet which is common for all the channels
The operation of coin operated chargers is very simple The user who wishes to
charge his cell phone has to first check out for the compatible charger jack in a channel
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 4
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Then he has to press select switch in order to make channel ready for charging the
selected channel will be indicated by a red LED
The channel will remain in selected mode for 30 sec Hence within 30 sec the user
has to first insert the predefined rupee coin and then has to press START switch which will
finally start the charging process for a predefined time and is indicated by a green LED
If failing to do so within 1 min will reset the channel and the user has to again
follow the same procedure
Any other channel selection is not considered within 30 sec of previous channel if
selected or until it has entered in to charging mode
Completion of charging will be indicated by an OFF green LED
23 Technology Used
Coin recognition using proximity switch(metal detector)
Constant voltage charger
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 3
DEVELOPMENT
STAGES amp
PROCESS
Development stages and process of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
31 DEVELOPMENT STAGES amp PROCESS
The complete development of this project can be divided into the following stages
Problem definition stage
Designing block diagram
Implementing circuits and components
Developing algorithm for software
Writing actual code for Microcontroller
Compiling the code
Burning the hex file into microcontroller with programmer
Testing and Running
311 Problem definition stage
This is the very first stage to develop any project It actually defines the aim
and the concept of the project At inconvenient times when access to a standard
charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is
designed to solve this problem The charger operates like a vending machine all a
user has to do is plug the mobile phone into one of the four adapters and insert a
coin the phone will then be given a micro-pulse fast charge in just 10 minutes
312 Designing block diagram
At this stage we have categorized the whole system into different individual
modules These modules (block diagrams) will be helpful in understanding the
concept and working of the integrated system It also simplifies the entire debugging
and testing process
313 Implementing circuits and components
This is the actual implementation of circuit of each block At this stage we
have actually designed each block separately and finally integrated them into the
complete working system
314 Developing for software
To get the logical flow of the software the development of algorithm having
a prominent role So that we have to analyze the complete system and organized the
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
algorithm in such a manner that one can understand the complete working of the
software
315 Writing actual code for Microcontroller
After the development of the algorithm and flowchart we have actually
translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so
that it can understand the instructions and run as per our requirement The
instructions are in ANSII C Language
316 Compiling the code
The hand written code on paper was then transferred into computer For that
we have used Keil pre-install on PC The Keil is a Computer Aided Program to
simulate the working of Microcontroller in real time without burning the software
into actual IC We simulated and compiled our program for error checking After
removing several compiling errors the program was converted into machine language
ie Philips hex format
317 Burning the hex file into microcontroller with Programmer
In this stage the compiled hex format file was downloaded or burned into
flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-
system programming software provided by the manufacturer itself
318 Testing and Running
This time we tested our project for actual working after loading the Software
into the microcontroller Any errors found were removed successfully This is the last
and final stage of development of our project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 4
BLOCK DIAGRAM
OF THE PROJECT
Block Diagram Brief Explanation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Then he has to press select switch in order to make channel ready for charging the
selected channel will be indicated by a red LED
The channel will remain in selected mode for 30 sec Hence within 30 sec the user
has to first insert the predefined rupee coin and then has to press START switch which will
finally start the charging process for a predefined time and is indicated by a green LED
If failing to do so within 1 min will reset the channel and the user has to again
follow the same procedure
Any other channel selection is not considered within 30 sec of previous channel if
selected or until it has entered in to charging mode
Completion of charging will be indicated by an OFF green LED
23 Technology Used
Coin recognition using proximity switch(metal detector)
Constant voltage charger
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 3
DEVELOPMENT
STAGES amp
PROCESS
Development stages and process of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
31 DEVELOPMENT STAGES amp PROCESS
The complete development of this project can be divided into the following stages
Problem definition stage
Designing block diagram
Implementing circuits and components
Developing algorithm for software
Writing actual code for Microcontroller
Compiling the code
Burning the hex file into microcontroller with programmer
Testing and Running
311 Problem definition stage
This is the very first stage to develop any project It actually defines the aim
and the concept of the project At inconvenient times when access to a standard
charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is
designed to solve this problem The charger operates like a vending machine all a
user has to do is plug the mobile phone into one of the four adapters and insert a
coin the phone will then be given a micro-pulse fast charge in just 10 minutes
312 Designing block diagram
At this stage we have categorized the whole system into different individual
modules These modules (block diagrams) will be helpful in understanding the
concept and working of the integrated system It also simplifies the entire debugging
and testing process
313 Implementing circuits and components
This is the actual implementation of circuit of each block At this stage we
have actually designed each block separately and finally integrated them into the
complete working system
314 Developing for software
To get the logical flow of the software the development of algorithm having
a prominent role So that we have to analyze the complete system and organized the
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
algorithm in such a manner that one can understand the complete working of the
software
315 Writing actual code for Microcontroller
After the development of the algorithm and flowchart we have actually
translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so
that it can understand the instructions and run as per our requirement The
instructions are in ANSII C Language
316 Compiling the code
The hand written code on paper was then transferred into computer For that
we have used Keil pre-install on PC The Keil is a Computer Aided Program to
simulate the working of Microcontroller in real time without burning the software
into actual IC We simulated and compiled our program for error checking After
removing several compiling errors the program was converted into machine language
ie Philips hex format
317 Burning the hex file into microcontroller with Programmer
In this stage the compiled hex format file was downloaded or burned into
flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-
system programming software provided by the manufacturer itself
318 Testing and Running
This time we tested our project for actual working after loading the Software
into the microcontroller Any errors found were removed successfully This is the last
and final stage of development of our project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 4
BLOCK DIAGRAM
OF THE PROJECT
Block Diagram Brief Explanation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 3
DEVELOPMENT
STAGES amp
PROCESS
Development stages and process of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
31 DEVELOPMENT STAGES amp PROCESS
The complete development of this project can be divided into the following stages
Problem definition stage
Designing block diagram
Implementing circuits and components
Developing algorithm for software
Writing actual code for Microcontroller
Compiling the code
Burning the hex file into microcontroller with programmer
Testing and Running
311 Problem definition stage
This is the very first stage to develop any project It actually defines the aim
and the concept of the project At inconvenient times when access to a standard
charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is
designed to solve this problem The charger operates like a vending machine all a
user has to do is plug the mobile phone into one of the four adapters and insert a
coin the phone will then be given a micro-pulse fast charge in just 10 minutes
312 Designing block diagram
At this stage we have categorized the whole system into different individual
modules These modules (block diagrams) will be helpful in understanding the
concept and working of the integrated system It also simplifies the entire debugging
and testing process
313 Implementing circuits and components
This is the actual implementation of circuit of each block At this stage we
have actually designed each block separately and finally integrated them into the
complete working system
314 Developing for software
To get the logical flow of the software the development of algorithm having
a prominent role So that we have to analyze the complete system and organized the
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
algorithm in such a manner that one can understand the complete working of the
software
315 Writing actual code for Microcontroller
After the development of the algorithm and flowchart we have actually
translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so
that it can understand the instructions and run as per our requirement The
instructions are in ANSII C Language
316 Compiling the code
The hand written code on paper was then transferred into computer For that
we have used Keil pre-install on PC The Keil is a Computer Aided Program to
simulate the working of Microcontroller in real time without burning the software
into actual IC We simulated and compiled our program for error checking After
removing several compiling errors the program was converted into machine language
ie Philips hex format
317 Burning the hex file into microcontroller with Programmer
In this stage the compiled hex format file was downloaded or burned into
flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-
system programming software provided by the manufacturer itself
318 Testing and Running
This time we tested our project for actual working after loading the Software
into the microcontroller Any errors found were removed successfully This is the last
and final stage of development of our project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 4
BLOCK DIAGRAM
OF THE PROJECT
Block Diagram Brief Explanation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
31 DEVELOPMENT STAGES amp PROCESS
The complete development of this project can be divided into the following stages
Problem definition stage
Designing block diagram
Implementing circuits and components
Developing algorithm for software
Writing actual code for Microcontroller
Compiling the code
Burning the hex file into microcontroller with programmer
Testing and Running
311 Problem definition stage
This is the very first stage to develop any project It actually defines the aim
and the concept of the project At inconvenient times when access to a standard
charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is
designed to solve this problem The charger operates like a vending machine all a
user has to do is plug the mobile phone into one of the four adapters and insert a
coin the phone will then be given a micro-pulse fast charge in just 10 minutes
312 Designing block diagram
At this stage we have categorized the whole system into different individual
modules These modules (block diagrams) will be helpful in understanding the
concept and working of the integrated system It also simplifies the entire debugging
and testing process
313 Implementing circuits and components
This is the actual implementation of circuit of each block At this stage we
have actually designed each block separately and finally integrated them into the
complete working system
314 Developing for software
To get the logical flow of the software the development of algorithm having
a prominent role So that we have to analyze the complete system and organized the
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
algorithm in such a manner that one can understand the complete working of the
software
315 Writing actual code for Microcontroller
After the development of the algorithm and flowchart we have actually
translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so
that it can understand the instructions and run as per our requirement The
instructions are in ANSII C Language
316 Compiling the code
The hand written code on paper was then transferred into computer For that
we have used Keil pre-install on PC The Keil is a Computer Aided Program to
simulate the working of Microcontroller in real time without burning the software
into actual IC We simulated and compiled our program for error checking After
removing several compiling errors the program was converted into machine language
ie Philips hex format
317 Burning the hex file into microcontroller with Programmer
In this stage the compiled hex format file was downloaded or burned into
flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-
system programming software provided by the manufacturer itself
318 Testing and Running
This time we tested our project for actual working after loading the Software
into the microcontroller Any errors found were removed successfully This is the last
and final stage of development of our project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 4
BLOCK DIAGRAM
OF THE PROJECT
Block Diagram Brief Explanation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
algorithm in such a manner that one can understand the complete working of the
software
315 Writing actual code for Microcontroller
After the development of the algorithm and flowchart we have actually
translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so
that it can understand the instructions and run as per our requirement The
instructions are in ANSII C Language
316 Compiling the code
The hand written code on paper was then transferred into computer For that
we have used Keil pre-install on PC The Keil is a Computer Aided Program to
simulate the working of Microcontroller in real time without burning the software
into actual IC We simulated and compiled our program for error checking After
removing several compiling errors the program was converted into machine language
ie Philips hex format
317 Burning the hex file into microcontroller with Programmer
In this stage the compiled hex format file was downloaded or burned into
flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-
system programming software provided by the manufacturer itself
318 Testing and Running
This time we tested our project for actual working after loading the Software
into the microcontroller Any errors found were removed successfully This is the last
and final stage of development of our project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 4
BLOCK DIAGRAM
OF THE PROJECT
Block Diagram Brief Explanation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 4
BLOCK DIAGRAM
OF THE PROJECT
Block Diagram Brief Explanation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
41 Block Diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10
Fig 41 Block diagram of the project
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
42 Brief Explanation
421 POWER SUPPLY
Power supply is used to deliver power to the circuit It delivers +5Vdc to
microcontroller and other peripherals and +12Vdc delivers power to relay
422 COIN INPUT AND LEVEL CONVERTOR
Coin input is a sensor which senses a metal and produces an output voltage This
voltage is high as compared to the input required for microcontroller
Hence a level shifter is used to bring down the voltage level which could be
readable to microcontroller
423 START SWITCH
Start switch is used to start the charging process of a
mobile phone
424 RS232 INTERFACING TO PC
RS 232 is a protocol used for communication between
computer and microcontroller It is also used for
programming the microcontroller in its ISP (in system
programming) mode
425 CHANNEL READY INDICATOR
It provides visual indication for the channel which is in
charging mode
426 DARLINGTON PAIR ARRAY
Darlington pair array is used as a relay driver
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
427 CHANNEL IN CHARGE INDICATION
It provides visual indication for the channel which is in
charging mode
428 RELAY ARRAY
Relay array consists of relays for each channel to
provide electromechanical switching in between charger and
mobile phone
429 CHARGER ARRAY
Charger array is used to provide charging power to the
mobile phones through the electromechanical switches
4210 CELL PHONE TO CHARGE
Channel select switch is used for selecting a channel on
which the mobile phone is to be charged
4211 MICROCONTROLLER
Microcontroller is used to control the whole operation of
the device Microcontroller reads input signal from input
device and triggers the output device According to the
conditions defined in the microcontroller by the programmer
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 5
CIRCUIT
DIAGRAM
EXPLANATION
Circuit diagram
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Circuit diagram explanation Working
51 POWER SUPPLY CIRCUIT
511 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14
Fig51 Circuit diagram of the power supply
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
Bridge RectifierTRANSFORMER
Filter Voltage regulator Load
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
512 WORKING
Transformer
A step-down transformer is used to achieve our requirements of the power
supply It steps down high voltage ac mains to low voltage ac mains
Bridge Rectifier
A bridge rectifier makes use four diodes in a bridge arrangement to achieve
full wave rectification This is a widely used configuration both with individual
diodes wired and with single component bridges where the diode bridge is wired
internally It also converts ac to dc but the dc output is varying
One advantage of a bridge rectifier over a conventional full-wave rectifier is
that with a given transformer the bridge rectifier produces a voltage output that is
nearly twice that of the conventional full-wave circuit
Filter
The output of the rectifier is a pulsating dc wave We need a constant dc
output To do this we need to filter out the oscillation from the pulsating dc wave
This is obtained with a diode capacitor combination
Voltage Regulator
A voltage regulator is used for voltage regulation in the circuit This provides
a protection to the circuits in the case of fluctuations It eliminates ripples by setting
dc output to fixed voltages
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15
Fig 52 Block diagram of the power supply
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Load
The load can be anything which wants to switch ON by using power supply
513 CIRCUIT DIAGRAM EXPLANATION
Regulated power supplies are commonly used in engineering projects Power
supply is food of any circuit
+5V SUPPLY UNIT
+5V supply is obtained from the +5V supply unit for microcontroller and
digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down
transformer having a capacity of 500mA
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 9VThis low voltage is rectified with the help
of bridge rectifier The ripples are minimized with the help of capacitor filter to get a
smooth DC supply The rating of the chosen capacitor filter is 1000microF
The regulated DC voltage is obtained by using a regulator IC 7805 In the
case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at
Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the
output of regulator IC to eliminate the voltage oscillations at the output due to the large
voltage oscillations at the input of the regulator
+12V SUPPLY UNIT
The plusmn12 V supply required by the relay is provided by the 12V supply circuit
arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a
step down transformer having a capacity of 1A and the center tap of the transformer is
grounded This low voltage is rectified with the help off bridge rectifier
Since the input voltage to the regulator IC should be more than its output
voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with
the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor
filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs
For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC
7912 is used
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and
the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is
connected at the output as shown in figure to eliminate the voltage oscillations at the
output due to the large voltage oscillations at the input of the regulator
52 CONSTANT VOLTAGE CHARGER
521 CIRCUIT DIAGRAM
Fig 53 Circuit diagram of the battery charger
522 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Constant-voltage (often called constant-potential) chargers maintain nearly the same
voltage input to the battery throughout the charging process regardless of the batterys state
of charge Constant-voltage chargers provide a high initial current to the battery because of
the greater potential difference between the battery and charger
A constant-voltage charger may return as much as 70 of the previous discharge in
the first 30 minutes This proves useful in many battery applications involving multiple
discharge scenarios As the battery charges its voltage increases quickly This reduces the
potential that has been driving the current with a corresponding rapid decrease in charge
current as depicted in the illustration below As a result even though the battery reaches
partial charge quickly obtaining a full charge requires prolonged charging
Given this behavior constant-voltage chargers are frequently found in applications
that normally allow extended charging periods to attain full charge Constant-voltage
chargers should not be used where there is frequent cycling of the battery Repeated
discharges without returning the cell to its full charge will eventually decrease the battery
capacity and may damage individual cells
Fig 54An Illustration graph of the charging function of constant battery charger
Constant-voltage chargers are most often used in two very different modes as a fast
charger to restore a high percentage of charge in a short time or as a float charger to
minimize the effects of overcharge on batteries having infrequent discharges
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
53 RELAY DRIVER CIRCUIT
531 CIRCUIT DIAGRAM
532 CIRCUIT DIAGRAM EXPLANATION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19
Fig 55 Relay driver circuit
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Input from the controller is connected to the relay card through connector J1 which
carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1
pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13
These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of
relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in
series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V
and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of
relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to
NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin
3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of
RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2
is used to connect power supply to relay card
533 WORKING
While taking Relay1 (RL1) into consideration we will discuss the working of relay
card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor
of the IC are in cut off region which causes an open circuit so there is no current flow
flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is
applied to the two pin1 of IC U1 the internal transistor goes in to active region and
completes the path ie provide ground to the relay coil so the current flows through the
LED activating the relay
As the current flows through the relay coil it gets energized and switch over the
contacts ie common and normally open contact get connected and provide a path to flow
current from J11 ie charger into the load connected at J4 hence the cell phone charging
process starts The same above process is applies for all relays If LED is fused or
damaged the path will be open and relay will not be energized and if relay is damaged the
led will not be illuminated So the LED here is used as a FAULT indicator and a
CHARGING ON indicator
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
54 MICROCONTORLLER CIRCUIT
541 CIRCUIT DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
542 CIRCUIT DIAGRAM EXPLANATION
CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with
the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to
port P04 through J4 and START switch is connected to port P05 through SW5
Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to
P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5
Output for relay card is taken on port P14 to P17
Components C1 R1 and push button S1 forms reset circuit which provides a power
on reset for the micro controller and even provide manual reset Crystal XL1 is a
110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are
22pf capacitor used as loading capacitor for crystal
Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and
RN2 resistance network
IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between
the proximity switch and microcontroller and convert its output readable to microcontroller
IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish
communication between PC and a microcontroller through connector J3
Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing
communication process
Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate
power supply connection
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
543 PORT ASSIGNMENTS FOR 89V51RD2FN
P00 = switch1 for channel 1
P01 = switch2 for channel 2
P02 = switch3 for channel 3
P03 = switch4 for channel 4
P04 = switch5 for coin input sensor (proximity switch)
P05 = switch6 for start charging
P10 = channel 1 red LED1 (ready system)
P11 = channel 2 red LED2 (ready system2)
P12 = channel 3 red LED3 (ready system3)
P13 = channel 4 red LED4 (ready system4)
P14 = channel 1 relay (start system1)
P15 = channel 2 relay (start system2)
P16 = channel 3 relay (start system3)
P17 = channel 4 relay (start system4)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 6
LIST OF THE
COMPONENTS
List of the components
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
61 LIST OF THE COMPONETS
RESISTORS
CAPACITORS
LIGHT EMITING DIODES (LEDS)- Green Red
RELAYrsquoS-
TRANSFORMERS
RECTIFIER BRIDGES (W 10)
OSCILLATOR
SWITCHES- Push switches
DARLINGTON PAIR IC (ULN2003a)
SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812
SERIAL COMMUNICATION DRIVER IC (MAX 232)
OPTOCOUPLER IC (4N33)
MICROCONTROLLER IC (89V51 RD2)
RELIMATE CONNECTOR- 2 pin amp 4 pin
RS-232 PORT CONNECTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 7
INTRODUCTION
OF COMPONENTS
Working of components
Features or Uses of components
Testing of components
71 RESISTOR
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
711 WORKING
Resistors limit current Resistors are considered to be the most used and the most
important component of all the electronic circuits Resistors resist the flow of electrical
current The higher the value of resistance (measured in ohms)
the lower the current will be
712 TESTING
Read the indicated color code value then select the OHM-scale within but not way
below the indicated value A resistor is good if its resistance is close to the indicated
Tolerance should be considered with the ohmmeter reading While no resistance reading at
all on the ohmmeter scale settings the resistor is open A zero resistance reading on all
ohmmeter scale settings resistor is shorted
713 SPECIFICATIONS
To completely specify a resistors characteristics requires knowledge of the following
parameters-
bull Value
bull Tolerance
bull Temperature Coefficient
bull Power Rating
The specification of a resistor may be marked on its surface using either of two
systems of coding The first of these uses colored bands known as the rsquocolour codersquo and
the second more recent system uses a combination of alpha-numeric characters
7 2 CAPACITOR
721 WORKING
When DC voltage is applied to the capacitor an electric charge is stored on each
electrode While the capacitor is charging up current flows The current will stop flowing
when the capacitor has fully charged Capacitors find use
in circuits for a variety of purposes They are used in
time delay generation RC circuits In power supplies for filtering and power supply
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
decoupling as blocking capacitors for power factor correction and motor starting in LC
tank circuits and so on
722 TESTING
To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester
negative probe to the capacitor positive terminal the positive probe to the negative terminal
A good indication for electrolytic capacitor shows the meter needle deflecting towards zero
and moves back again to infinite resistance position A defective indication for an
electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point
which is an indication that the capacitor is shorted
73 LIGHT EMITING DIODE (LED)
731 WORKING
LEDs are special diodes that emit light when
connected in a circuit They are frequently used as pilot lights in electronic appliances to
indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed
the heart of an LED the semi-conductor chip
In our project Green LED are used here for mainly two purpose
a Charging ON indication (when ON)
b Channel fault indication (always OFF)
732 TESTING
The good and working LED will then light up or glow a busted LED will not LEDs
must have a resistor in series to limit the current to a safe value for quick testing purposes a
1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be
directly connected to a battery or power supply It will be destroyed the LED
733 FEATURES
Single color
High bright output
Low power consumption
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
High reliability and long life
734 Descriptions
Dice material GaInN
Emitting Color Super Bright White
Device Outlineφ5mm Round Type
Lens Type Water Clear
74 RELAY
741 WORKING
A relay is an electrically operated switch Current
flowing through the coil of the relay creates a magnetic field
which attracts a lever and changes the switch contacts The coil
current can be on or off so relays have two switch positions and
most have double throw (changeover) switch contacts
Relays are like remote control switches and are used in
many applications because of their relative simplicity long life
and proven high reliability
742 USES
The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit
It is also used in places where only one signal can be used to control a lot of circuits
The application of relays started during the invention of telephones They played an
important role in switching calls in telephone exchanges They were also used in
long distance telegraphy They were used to switch the signal coming from one
source to another destination
743 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
A relay will usually have a coil pole terminal and a set of
contacts The set of contacts that are open when the relay is not
energized are called normally open (NO) contacts and the set of
contacts that are closed when the relay is not energized are called
normally closed (NC) contacts The following steps can be used to perform the testing of
the relay using a multimeter
Keep the multimeter in the continuity check mode
Check for continuity between the NC contacts and pole
Check for discontinuity between NO contacts and the pole
Now energies the relay using the rated voltage For example use a 9V battery for
energizing a 9V relay The relay will engage with clicking sound
Now check for continuity between NO contacts and pole
Also check for discontinuity between NC contacts and pole
As a final test measure the resistance of the relay coil using a multimeter and check
whether it is matching to the value stated by the manufacturer
If all the above tests are positive we can conclude that the relay is healthy
75 TRANSFORMER
751 WORKING
A transformer is a device that transfers electrical energy
from one circuit to another through inductively coupled
electrical conductors A changing current in the first circuit (the
primary) creates a changing magnetic field
This changing magnetic field induces a changing voltage in the second circuit (the
secondary) This effect is called mutual induction
If a load is connected to the secondary circuit electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the
load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction
of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the
number of primary turns
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
By appropriate selection of the numbers of turns a transformer thus allows an
alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by
making it less
752 TESTING
1 The ohm meter is the deciding factor Putting the ohm meter on the lowest
scale and then adjusting the knob to verify its reading is an easy step to the
reading of the ohm
2 To check the resistance of the coil unplug or unsolder the leads of the
transformer from its circuit and measure the resistance of each coil
3 The next step is to test each coil for shorts to other coils
76 RECTIFIER BRIDGE (W 10)
761 WORKING
A diode bridge rectifier is a device for converting AC or
alternating current electricity into DC or direct current AC
electricity goes from positive to negative constantly whereas DC
always flows in the same direction
AC electricity is more efficient to transmit and easier to
convert into different voltages However most appliances need DC current to run A diode
bridge rectifier is the most common type of power supply used to provide this current In
our project W10 is a bridge rectifier which provides on single semiconductor chip
77 OSCILLATOR
771 Working
An oscillator puts out an endless series of pulses The output
constantly goes from 0 volts to Vcc and back to 0 volts again Almost
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
all digital circuits have some type of oscillator This stream of output pulses is often
called a clock One of the most important features of any oscillator is its frequency stability
or in other words its ability to provide a constant frequency output under varying load
conditions Some of the factors that affect the frequency stability of an oscillator include
temperature variations in the load and changes in the DC power supply Frequency stability
of the output signal can be improved by the proper selection of the components used for the
resonant feedback circuit including the amplifier but there is a limit to the stability that can
be obtained from normal LC and RC tank circuits
In our project instead of 12MHz crystal 110592MHz is used because it can be
divided to give you exact clock rates for most of the common baud rates for the UART
especially for the higher speeds (9600 19200) These crystals are readily available and
commonly used
78 SWITCH
781 WORKING
The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts
Each set of contacts can be in one of two states either closed meaning
the contacts are touching and electricity can flow between them or
open meaning the contacts are separated and the switch is non
conducting The mechanism actuating the transition between these two
states (open or closed) can be either a toggle (flip switch for continuous on or off) or
momentary (push-for on or push-for off) type
782 USES
In electronics a switch is an electrical component that can break an electrical
circuit interrupting the current or diverting it from one conductor to another
783 TESTING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the switch is ON it looks and acts like a wire When the switch is OFF there is
no connection Switch can tested by using multimeter in continuity range
79 DARLINGTON PAIR IC (ULN2003a)
791 WORKING
The Darlington transistor (often called a Darlington pair) is a
compound structure consisting of two bipolar transistors (either
integrated or separated devices) connected in such a way that the
current amplified by the first transistor is amplified further by the
second one This configuration gives a much higher current gain than
each transistor taken separately and in the case of integrated devices
can take less space than two individual transistors because they can
use a shared collector
Integrated Darlington pairs come packaged singly in
transistor-like packages or as an array of devices (usually eight) in an integrated circuit
The Darlington transistor array used is ULN2003 Applications include relay
drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line
drivers and logic buffers Each input of this device has a zener diode and resistor in series
to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor
for each Darlington pair for operation directly with TTL or 5-V CMOS devices
792 FEATURES
The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington
transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs
with common-cathode clamp diodes for switching inductive loads The collector-current
rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for
higher current capability
710 SERIES VOLTAGE REGULATER IC (78XX)
7101 WORKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Voltage Regulator (regulator) usually having three legs converts varying input
voltage and produces a constant regulated output voltage They are available in a variety of
outputs
The most common part numbers start with the numbers 78 or 79 and finish with two
digits indicating the output voltage The number 78 represents positive voltage and 79
negative one The 78XX series of voltage regulators are designed for positive input
The LM78XX series typically has the ability to drive current up to 1A For
application requirements up to 150mA 78LXX can be used As mentioned above the
component has three legs Input leg which can hold up to 36VDC Common leg (GND) and
an output leg with the regulators voltage
As a general rule the input voltage should be limited to 2 to 3 volts above the output
voltage The LM78XX series can handle up to 36 volts input be advised that the power
difference between the input and output appears as heat If the input voltage is unnecessarily
high the regulator will overheat Unless sufficient heat dissipation is provided through heat
sinking the regulator will shut down
711 SERIAL COMMUNICATION DRIVER IC (MAX 232)
7111 WORKING
The MAX-232 It includes a Charge Pump which generates
+10V and -10V from a single 5v supply
This IC also includes two receivers and two transmitters in
the same package This is handy in many cases when we only want to
use the Transmit and Receive data Lines We dont need to use two chips one for the
receive line and one for the transmit There are also many variations of these devices The
large value of capacitors are not only bulky but also expensive Therefore other devices are
available which use smaller capacitors and even some with inbuilt capacitors However the
MAX-232 is the most common and thus we will use this RS-232 Level Converter
Dual Charge-Pump Voltage Converter
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the
V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-
output
712 OPTOCOUPLER IC (4N33)
7121 WORKING
In electronics an opto-isolator (or optical isolator optocoupler photocoupler or
photoMOS) is a device that uses a short optical transmission path to transfer a signal
between elements of a circuit typically a transmitter and a receiver while keeping them
electrically isolated mdash since the signal goes from an electrical signal to an optical signal
back to an electrical signal electrical contact along the path is broken
Optocouplers typically come in a small 6-pin or 8-pin IC package but are
essentially a combination of two distinct devices an optical transmitter typically a gallium
arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or
light-triggered diac The two are separated by a transparent barrier which blocks any
electrical current flow between the two but does allow the passage of light
The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a
silicon photo Darlington sensor Switching can be achieved while maintaining a high degree
of isolation between driving and load circuits These Optocouplers can be used to replace
reed and mercury relays with advantages of long life high speed switching and elimination
of magnetic field
713 MICROCONTROLLER IC (89V51 RD 2 )
713 WORKING
The P89V51RD2 is an 80C51 microcontroller with 64
kB Flash and 1024 bytes of data RAM
A key feature of the P89V51RD2 is its X2 mode option
The design engineer can choose to run the application with the conventional 80C51 clock
rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
achieve twice the throughput at the same clock frequency Another way to benefit from this
feature is to keep the same performance by reducing the clock frequency by half thus
dramatically reducing the EMI
The Flash program memory supports both parallel programming and in serial In-
System Programming (ISP) Parallel programming mode offers gang-programming at high
speed reducing programming costs and time to market ISP allows a device to be
reprogrammed in the end product under software control The capability to fieldupdate the
application firmware makes a wide range of applications possible The P89V51RD2 is also
In-Application Programmable (IAP) allowing the Flash program memory to be
reconfigured even while the application is running
714 RELIMATE CONNECTOR
7141 WORKING
These are wire to board type connectors used to facilitate
proper and firm electrical connection between the relay card and
microcontroller card
The connector has following specifications
No of Ways 2-20
Voltage Rating 250V AC DC
Current Rating 3A AC DC
Contact Resistance 20mW max
Insulation Resistance 1000MW min
Dielectric Withstanding 1000V ACminute
Crimp Terminal Wire Size 22-28 AWG (American wire gauge)
The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the
connector is it provides a fast and easy connection and disconnection it also avoids polarity
conflicts
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
715 RS-232 PORT CONNECTOR
7151 WORKING
Almost all digital devices which we use require either TTL
or CMOS logic levels Therefore the first step to connecting a
device to the RS-232 port is to transform the RS-232 levels back
into 0 and 5 Volts This is done by RS-232 Level Converters
Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232
Receiver Each package contains 4 inverters of the one type either Drivers or Receivers
The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a
problem in many instances where only a single supply of +5V is present
CHAPTER 8
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
IMPLIMENTATION
OF THE PCB
Components layout designing
Developing or Etching the PCB
Other operations like Drilling Cutting Tinning
81 IMPLIMENTATION OF THE PCB
A proper PCB ensure that various circuit components are interconnected as per the
circuit diagram once they have been placed on the PCB in their proper positions and
subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating
base material to which is permanently attached a flat metallic network of conducting path
whose dimension depends upon the current that can be handled by them Four PCBrsquoS used
for this project is single one
The basic material used may be resin coated paper fiber glass ceramic and the flat
board configuration however is most widely used and it may be of the nature of the single
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors
which ensures adequate and permanent low resistance coupling
811 BOARD DESIGN
PCB designed is the most important and requires great care during work In this case
great care must be taken while tracing the circuit or layout on the board Because once PCB
is designed it is virtually impossible to alter it While designing a circuit designer should
take care to avoid crossing of conducting path (tracks) as possible Crossover are
unavoidable then only of the jumper can be used A circuit board carrying on both sides can
also help to solve this problem when circuit is complicated
812 THE MASTER DIAGRAM
The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo
which is commonly made twice as the finished circuit since this makes the working on that
much easier especially when circuit is complicated photography eventually reduces the
size of diagram to that of the circuit before proceeding we must know some rules regarding
the designing -
a The space between the conductors must be strictly controlled to avoid the possibility
of electrical discharges or unwanted capacitance The amount by which the mater
diagram is to reduce in size is thus a critical deign feature
b The conductor must be wider in those part of the circuits that are going to handle
large current must be handle without undue temperature of conductors
c The minimum width of copper should not generally be less than about 15mmThis
is related to mechanical strength rather than electrical properties and it also ensure
that strips remains securely bounded to the base material
d The points where the component holes for component lead wire occurs must be sited
to suit the dimensions of the component and dimensions between lead-out wire so
that the components can be situated correctly on finished board The conductor is
also main large at the point of holes
813 PCB MAKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When the mater diagram probable twice the size of real PCB has been evolved the
test major step consists of etching or dissolving the unwanted metal from copper claded
board to create a circuit as depicted by master diagram It must be stressed that very
accurate checking master is essential at this stage Then the master point is mounted on a
special frame on easy facing of a larger camera and with the aid of the very powerful
illumination a master diagram is clearly photographed on a glass sensitive plate This is
developed to give photographic negative Next is called ldquostep and repeat camerardquo It is
brought into operation This comprises the camera body mounted so that sideways after
each exposure In this way number of copies of the original master diagram is set out
exactly to cover standard sheet of copper clad laminate laboratory method of making PCB
In case of simple and need of number of less PCB economic and advisable to use the
following lab method of PCB making
Planning The Circuit
It is not a particular difficult There are several important factors that need not be
taken into account if the finished device is to work properly we must consider gain factor
and ensure that the input and output parts are sufficiently well isolated to avoid the
possibility We must also ensure that conductors and components carrying high frequency
current are well separated from the part of the circuit We are also to make sure that all
components need to return to earth are properly connected and that possibility of common
impedance arising earth returned
Circuit is totally eliminated by making all earth as substantial possible consistent
with nature of design Other factors that have to successfully studied include availability of
adequate return points on board and itrsquos mounting from accessibility of switch connection
made for mechanical fixing ventilation effect of vibration
Cleaning The Board
The copper side of the board must be thoroughly cleaned before circuit plan is
transferred to it This is important because even slightest trace of graze (from figure of
instance) will impure the etching process and when the circuit plan has been neatly
transferred to copper in this manner the board is held under running tap and the allowed to
dry before resist is applied
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Transforming the Plan
Now once cleaning is done plan has to transfer on copper surface of PCB material
A convenient way to do this is simply put the carbon paper between a copper surface of the
board and working plan and carefully trace the lines of original plan with a ball pen
Resist
Resist is nothing more than a substrate that is unaffected by presence etching
chemicals It is usually colored so that it can be easily seen the copper surface when plan is
clearly worked on clean copper that are to be left in fact as the copper conductor must be
covered when resists the leaguer type of paints possess good resist properties but
disadvantage of relatively long time taken for drying It is essential to resist through
hardening before etching is started Nail polished are better as they quickly and are less
difficult to remove
To overcome this drying effect and to achieve the sharp edge of the trace on the
PCB Now-a-days etching taps along with IC pads are commonly used To this chances of
short circulating due to paints are completely the avoid etching tapes and pads are available
in different sizes
Correcting Error
When a result has been thoroughly hardened any errors that have been made can
usually be corrected by gently scratching away with knife To ensure clear out lines round
edges of copper conductors on board the resist must be applied with steady band
Etching
Next comes etching of unwanted copper amp whether a small single is all that is
required as quantity of board to be produce certain precautions must be taken before
operation is commenced the most used etch amp I ferrite chloride to this is added small
quantity of HCL to accelerate But not critical as lab construction concerned A good
etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15
grams of water
Agitation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Small plastic bath is ideal for storing the etchant process Depth of liquid for storing
the etchant process The depth of liquid must be sufficient to completely cover laminate the
laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the
gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant
temperature and thickness of copper foil
Finishing Off
When all unwanted copper is dissolved from areas between conductor board should
be taken from an etchant amp washed in water The resist must be removed using proper
solvent After this the copper surface must be polished with any kind of cleaner It should be
seen that there is no slight incomplete etching between the conducting parts of the PCB The
PCBrsquos are coated coating material for protection in lab coating material itself it a soldier
This process is called Tinning This process of coating involve track with soldier
Advantage of tinning the effect of environment of conductors then PCB is drilled
ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit
Assembling On PCB
After the holes are drilled the component have to be assembled on PCB before
assembling the components it is necessary to clean soldering iron in order to get easy amp
accurate soldering Removing impurity particles that are gathered on iron bit due to
repetitive use cleans soldering iron
CHAPTER 9
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
SOLDERING
TECHNIQUE
Technique for good soldering
91 SOLDERING TECHNIQUE
For soldering of any joints first the terminal to be soldered are cleaned to remove
oxide film or dirt on it If required flux is applied on the points to be soldered
Now the joint to be soldered is heated with the help of soldering iron Heat
applied should be such that when solder wire is touched to joint it must melt
quickly
The joint and the soldering iron is held such that molten solder should flow
smoothly over the joint
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
When joint is completely covered with molten solder the soldering iron is re-
moved
The joint is allowed to cool without any movement
The bright shining solder indicates good soldering
In case of dry solder joint a air gap remains in between the solder material and
the joint It means that soldering is improper This is removed and again solder-
ing is done
Thus this way all the components are soldered on P C B
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 10
PCB LAYOUTS
Schematic diagram
Bottom and top layout
101 POWER SUPPLY CARD
1011 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1012 LEGEND MARKING
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46
Fig1011 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1013TOP LAYER
1014 BOTTOM LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47
Fig1013 Top layer of power supply
card
Fig1014 Schematic diagram of power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
102 BATTERY CHARGER CARD
1021 SCHEMATIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48
Fig1021 Schematic diagram of battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
103 RELAY CARD
1031 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49
Fig1031 Schematic diagram of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1032 RELAY CARD LEGEND MARKING
1033 TOP LAYER
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50
Fig1032 Legend marking of Relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1034 BOTTOM LAYER
104 MICROCONTROLER CARD
1041 SCHIMETIC DIAGRAM
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51
Fig1034 Bottom layer of Relay card
Fig1041 Schematic diagram of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1042 ALL LAYERS
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52
Fig1042 All layer of microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 11
INTRODUCTION
OF SOFTWARE
Keil (microVision 2)
Eagle (Easily Applicable Graphical Layout Editor)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
111 Keil (microVision 2)
1111 Introduction to C51 Cross Compiler
The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to
generate fast compact code for the 8051 microcontroller family The C51 Compiler
generates object code that matches the efficiency and speed of assembly programming
Using a high-level language like C has many advantages over assembly language
programming
Knowledge of the processor instruction set is not required Rudimentary knowledge of
the memory structure of the 8051 CPU is desirable (but not necessary)
Details like register allocation and addressing of the various memory types and data
types is managed by the compiler
Programs get a formal structure (which is imposed by the C programming language) and
can be divided into separate functions This contributes to source code reusability as
well as better overall application structure
The ability to combine variable selection with specific operations improves program
readability
Keywords and operational functions that more nearly resemble the human thought
process may be used
Programming and program test time is drastically reduced
The C run-time library contains many standard routines such as formatted output
numeric conversions and floating-point arithmetic
Existing program parts can be more easily included into new programs because of
modular program construction techniques
The language C is a very portable language (based on the ANSI standard) that enjoys
wide popular support and is easily obtained for most systems Existing program
investments can be quickly adapted to other processors as needed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1112 Software Development Cycle in Keil
When we use the Keil Software tools the
project development cycle is roughly the same as
it is for any other software development project
1 Create a project select the target chip from the
device database and configure the tool settings
2 Create source files in C or assembly
3 Build your application with the project
manager
4 Correct errors in source files
5 Test the linked application A block diagram of
the complete 8051 tool set may best illustrate the
development cycle
112 Eagle (Easily Applicable Graphical Layout Editor)
The EAGLE is an editor which is easy-to-use yet powerful tool for designing
printed circuit boards (PCBs) It is a complete platform for the development of any type of
complicated amp sophisticated multilayered PCBs This software consist of the following tool
1121 Schematic Editor
In this one can develop amp design circuits for the required PCB
1122 Layout Editor
In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55
Fig 111 Software development in KEIL
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1123 Library Editor
This is very useful in case of customized component design that does not occur in the predefined library according to our need
1124 Auto Router
This is an artificial intelligence based tool or subroutine that can do auto routing of
the PCB tracks designed
1125 Cam Processor
This is used to finally print the various layers of the designed PCB viz Top Layer
Bottom Layer Component Layer Masking Layer etc
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1
Start
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 12
INTRODUCTION
OF
PROGRAMMING
Flowchart of programming
Program code
121 Flowchart
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
2
flag9==1
flag9=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
flag11==1
flag11=1 flag11=0 flag4=0
REady_LED4=0
Sw2_op (P01) ==0
My delay (10)
3 3
flag2=1 disp2=1 k2=0
3
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
4
flag11==1
flag11=0 flag4=0 REady_LED4=0
flag11=1
My delay (10)
flag3=1 disp3=1 k3=0
k1==0||k2==0||k4==0
Sw3_op (P02) ==0
5
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
flag5==1
5
flag11==1
flag7=1
flag7==1
flag7=0 flag2=0 REady_LED2=0
6
flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0
flag11=0 flag4=0 REady_LED4=0
flag11=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
6
My delay (10)
flag4=1 disp4=1 k4=0
k1==0||k2==0||k3==0 flag5==1
7
Sw4_op (P03) ==0
flag5=1 flag5=0 flag1=0 REady_LED1=0
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
7
flag7==1
flag9==1
flag7=1
flag7=0 flag2=0 REady_LED2=0
flag9=0 flag3=0 REady_LED3=0
flag9=1
Sw5_op A(P04) ==0
My delay (10)
8
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
9
flag2==1
flag3==1
8
flag1==1
flag4==1 flag5=1 disp5=1
flag9=1 disp5=1
flag7=1 disp5=1
flag11=1 disp5=1
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
Sw6_op (P05) ==0
My delay (10)
flag2==1 ampamp flag7==1
flag3==1 ampamp flag9==1 9
flag1==1 ampamp flag5==1 flag6=1 disp6=1
flag8=1 disp6=1
10
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
10
flag4==1 ampamp flag11==1
flag10=1 disp6=1
flag12=1 disp6=1
flag8==1
flag10==1
11
flag6==1
i++
l++
j++
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
flag12==1
M++
11
Stop
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
122 Program
includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H
define buzzerP2_0 buzzer indication
setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4
sbit sw5_op=P0^4 input switch5 for coin
sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit
output Led for indication
sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)
sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )
function prototype declaration
void my_delay(unsigned int value) DELAY FUCTION
void init_timer() timer 0 initialization function
variable declaration
bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
start of main programme
void main()
init_timer() call it timer initialization function
REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led
START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led
start of while loop
while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system
condition for switch1
if(flag1==1) check swich1 pressed if(disp1==1 )
REady_LED1=1 turn on Ready indication of led 1 disp1=0
if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion
if(iltk) loop will repeat for desired time of charging
if(igt=1000)
buzzer=1 turn on buzzer if (ii==20)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED1=1 turn on ready indication of led1
else if(ii==40)
REady_LED1=0ii=0
elseREady_LED1=0
START_LED1=1
else
START_LED1=0
k1=1 buzzer=0
REady_LED1=0 flag1=0
flag5=0flag6=0
condition for switch2
if(flag2==1) check swich2 pressed if(disp2==1)
REady_LED2=1 turn on ready 2 led indication
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp2=0
if(flag7==1) check coin is pressed if(flag8==1) START is pressed
if(jltk)
if(jgt1000) buzzer=1 if(jj==20)
REady_LED2=1else if(jj==40)REady_LED2=0jj=0
elseREady_LED2=0
START_LED2=1
else START_LED2=0
REady_LED2=0 k2=1 buzzer=0
flag2=0flag7=0flag8=0
j=0jj=0
condition for switch 3
if(flag3==1) check swich3 pressed
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if(disp3==1 )
REady_LED3=1 disp3=0
if(flag9==1) check coin is pressed if(flag10==1) START is pressed
if(lltk)
if(lgt1000) buzzer=1 if(ll==20)
REady_LED3=1else if(ll==40)REady_LED3=0ll=0
elseREady_LED3=0
START_LED3=1
else START_LED3=0
LED2=0 k3=1 buzzer=0
REady_LED3=0 flag3=0
flag9=0flag10=0
l=0ll=0
condition for switch 4
if(flag4==1) check swich4 pressed if(disp4==1 )
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
REady_LED4=1 disp4=0
if(flag11==1) check coin is pressed
if(flag12==1) START is pressed
if(mltk)
if(mgt1000)
buzzer=1 if(mm==20)
REady_LED4=1else if(mm==40)REady_LED4=0mm=0
elseREady_LED4=0
START_LED4=1
else START_LED4=0
buzzer=0 k4=1
REady_LED4=0 flag4=0
flag11=0flag12=0
m=0mm=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
while(1)
end of main programme
timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1
TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit
whenever specific time the interrupt will generate control will go in following function
void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw1_op==0 ) ready switch flag for system1
my_delay(10) CALL DELAY FUNCTION
flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0
if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP
if(flag7==1) SET THE FLAG
flag7=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED
IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw2_op==0 ) fready switch flag for system2
my_delay (10)
flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)
if(flag5==1)
flag5=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw3_op==0 ) ready switch flag for system3 my_delay(10)
flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)
if(flag7==1)
flag7=1
else
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag7=0flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag11==1)
flag11=1
elseflag11=0flag4=0REady_LED4=0
IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)
if(flag7==1)
flag7=1
elseflag7=0
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
flag2=0REady_LED2=0 if(flag5==1)
flag5=1
elseflag5=0flag1=0REady_LED1=0 if(flag9==1)
flag9=1
elseflag9=0flag3=0REady_LED3=0
IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1
if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
disp5=1 if(flag4==1 ) flag11=1 disp5=1
IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP
if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1
if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1
if(flag6==1)
i++ if (igt1000) ii++
if (flag8==1)
j++ if(jgt1000) jj++
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
if (flag10==1)
l++ if (lgt1000) ll++
if (flag12==1)
m++ if (mgt1000) mm++
DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 13
TROUBLE SHOOT
Troubleshoot
131 TROUBLE SHOOT
A newly assembled circuit does not work may be due to -
Faulty components
Improper soldering
Wrong connections
Also any stop in working after some period may be due to -
Component failure
Supply failure
Damaging of PCB
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fault finding is very essential if you want the circuit to operate properly
If a newly assembled circuit is not working properly check all the components and
circuit connections according to the diagram The circuit may not be working due to wrong
polarity of capacitor diode and wrong supply terminal connection Most of the times the
circuit does not work due to bad soldering Therefore proper procedure is followed to have
proper soldering
If faults are not observed during physical observations one should proceed for Hot
test ie Voltage measurement at different points for example at Input terminal etc
Resistance measurement is also done which is known as Dry test
During this project work some green LEDs was not glow then we checked it
continuity and replace it
Also relay was not properly worked therefore we replaced it Some ICs was get
heated after starting the project It happens because of some soldering points are shorted
during soldering PCB We solved that problem
CHAPTER 14
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
ADVANTAGES OF
THE PROJECT
Advantages
141 ADVANTAGES OF THE PROJECT
Simple and hand efficient Microcontroller based system
Fast charging capacity
Simple to operate
Ease of mobility
Facilitates connectivity for 90 of cellular phones
Less expensive
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Reduced man power
Low power consumption
It can offer emergency charging for 4sets of handsets synchronously
CHAPTER 15
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
DISADVANTAGES
OF THE PROJECT
Disadvantages
151 DISADVANTAGES OF THE PROJECT
It requires mains supply to work project
Due to limited charging channels till now there may be a possibility that
mobile phones of few brands cannot be connected for charging For this
purpose we have to use separate connectors for that specific brand differently
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
It does not bring a mobile from lsquodead to fully charged (full bars) just in 1
min
It does not have battery backup therefore it cannot be portable
CHAPTER 16
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPLICATIONS OF
THE PROJECT
Application
161 APPLICATIONS OF THE PROJECT
The coin based mobile phone charger is very useful to public for using coin to
charge for the mobile phone in any places
It is used for emergency charging purposes
It can be installed in malls railway stations bus stops and other public
places
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
The charger offers a unique revenue opportunity for a vast range of
businesses - from airports to pubs from universities to health clubs virtually
any location where there is a high footfall creating a large number of
potential users
It can be installed in offices and collages for pay charging facility
CHAPTER 17
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
FUTURE
DEVELOPMENT OF
THE PROJECT
FUTURE DEVELOPMENT OF THE PROJECT
171 FUTURE DEVELOPMENTOFTHE PROJECT
This project is very useful to people who are using mobile phone without charging
condition in public places
It will use with a stereo advertisement carrier that can display video advertisement
It will provide battery backup for make it portable
It will also provide SMS system in future
We can also increase the charging time by editing software of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 18
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
COST ANALYSIS
OF THE PROJECT
COST ANALYSIS OF THE PROJECT
181 COST ANALYSIS OF THE PROJECT
1811 Component list for power supply card
Footprint Quantity Designators Rate
Resistor
22K 1 R2 1
1K 1 R1 1
Capacitor
1000uf25V 1 C5 10
2200uf25V 1 C1 10
022uf 2 C6 C2 1
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
Table 1811 Component list for power supply card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 2 C4 C3 1
IC
BRIDGE W10 2 BR2 BR1 10
L7812CV (TO-220) 1 U2 8
L7805CV (TO-220) 1 U1 8
Connector
CON PHO 2PIN 2 J3 J2 16
CON PHO 3PIN 1 J1 12
LED3mm red 2 L1 L2 15
Heat sink (TO-220) 2 16
Total 955
1812 Component list for battery charger card
Footprint Quantity Rate
Capacitor
2200uf25V 1 1000
022uf 4 100
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
01uf 4 100
IC
BRIDGE W10 1 500
L7805CV (TO-220) 4 3200
Connector
CON PHO 2PIN 1 800
Relimate 2 pin 1 400
relimate 3 pin 4 2000
Heat sink (TO-220) 4 1200
TOTAL 9300
1813 Component list for Relay card
Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94
Table 1812Component list for battery charger card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
RELIM-4 1 J1 700 16 pin ic socket 1 400
Total 18900
1814Component list for controller card
Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95
Table 1813Component list for relay card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200
total 27000
1815 Miscellaneous material
Material Quantity Rate
electronic item
Transformer
TXR1 0-9-15 1 20000
0-9 1A
0-15 100mA
TXR2 0-9 1 16500
0-9 1A
Proximity switch 1 20000
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96
Table 1814Component list for microcontroller card
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Red push bottom 4 4000
Green push button 1 1000
Red led 5mm 4 800
Green led 5mm 4 800
Led holder 8 1600
Copper clad 2 4000
3 core cable 1 meter 1500
3 pin plug 1 3000
2 pin relimate wire 19 9000
3 pin relimate wire 5 3750
4 pin relimate wire 2 2000
mechanical items
Enclosure 1 25000
Acrylic sheet 2 X 1 30000
12mm cable gland 1 1000
Screw 3mm 33 2000
Screw 35mm 6 2400
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
10 mm spacers 100 1500
10mm insert to stud 50 10000
cable tie 2500
Total 162350
CHAPTER 19
APPENDIX
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98
Table 1815Component list for miscellaneous material
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
APPENDIX
191 APPENDIX
1911 78xx IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1912 W10 datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1913 4n33 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common
1914 MAX 232
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1915 ULN2003a IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
1916 89V51RD2 IC datasheet
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 20
CONCLUSION
CONCLUSION
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
201 CONCLUSION
The coin-operated mobile phone charger is already successfully installed in
hundreds of locations worldwide providing a unique service to the public and a source of
revenue for site providers The coin-operated mobile charger can be quickly and easily
installed in any business premises
The charger offers a unique revenue opportunity for a vast range of businesses ndash
from airports to pubs from universities to health clubs virtually any location where there is
a high footfall creating a large number of potential users
The charger can charge up to 4 different mobile phones simultaneously It will
extend low mobile phone talk time provide battery charging
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 21
IMAGES OF THE
PROJECT
Images of the project
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
211 IMAGES OF THE PROJECT
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113
fig211 lsquoCoin operated mobile battery charger
Fig212 Circuit arrangement of coin operated mobile battery charger
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig 216 Relay driver circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114
Fig 213 Constant voltage battery charger circuit
Fig214 Power supply circuit
Fig215 Metal detector proximity switch
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig217 Microcontroller circuit
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
Fig228 coin operated mobile battery charger project presentation
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
CHAPTER 22
BIBILOGRAPHY
BIBLIOGRAPHY
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118
ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo
221 BIBLIOGRAPHY
BOOKS
Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine
INTERNET LINKS
wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom
PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118