GSM based manufacturing industrial automation

INTRODUCTION

AIM AND OBJECTIVE

In some industries proper maintenance of the controlling system or industrial devices is crucial to deliver an

uninterrupted output. So to reduce the maintenance costs and to optimize critical monitoring system GSM

Based Industrial Automation Technology is used.

In this project a GSM server is implemented with PSOC mixed signal chip, sensors and relays. The GSM

Modem can provide the necessary data related to industry to a maintenance officer located anywhere at any

time. According to data received officer will take some action by sending some commands to PSOC chip

through mobile unit to GSM modem. PSOC chip decodes the commands and controls the industrial devices

through relays.

SCOPE OF THE PROJECT

The scope includes connecting the different control systems to relays for controlling the environment. The

PSOC microcontroller can be used for implementation of more complex systems for complex tasks like

controlling different systems like nuclear plants and reactors in the industry. It can also be used in the

system where there is a need of instrumentation, inverting and non inverting amplifiers.

AUTOMATION

Automation or industrial automation is the use of control systems such as computers to control industrial

machinery and processes, reducing the need for human intervention. In the scope of industrialization,

automation is a step beyond mechanization. Whereas mechanization provided human operators with

machinery to assist them with the physical requirements of work, automation greatly reduces the need for

human sensory and mental requirements as well. Processes and systems can also be automated. Automation

plays an increasingly important role in the global economy and in daily experience. Engineers strive to

combine automated devices with mathematical and organizational tools to create complex systems for a

rapidly expanding range of applications and human activities.

Industrial automation is the process of controlling and guiding the industrial equipment, i.e. process and

systems with less of the human intervention. The operation and control of the modern industrial equipment

and process needs lot of sensors to monitor various parameters of the systems.

Industrial automation is the process of controlling and guiding the industrial equipment, i.e. process and

systems with less of the human intervention. The operation and control of the modern industrial equipment

and process needs lot of sensors to monitor various parameters of the systems.

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Importance of Automation

Automation can improve productivity and quality. In order to receive these benefits, educating the workers

on the machinery is necessary. Companies must contemplate their objectives of automating before

incorporating any machinery.

As factory automation technology becomes more capable, more functional and ubiquitous its

meaning and purpose take on many interpretations.

Factory automation delivers increased product and process information, and of course, improves

product quality.

Technology is used in so many ways and for so many different ends that it is almost impossible to

have a single definition that includes all the solutions factory automation delivers.

MVI's RPM system, in effect, documents the way a company manages its people.

Its various data templates can be configured to address management and executive information

needs.

It presents real-time data that will help them to do something with the information and make an

informed decision.

System monitoring showed that unit costs varied by as much as 50 percent over the three daily

shifts.

Providing proper training to the operators led to increased productivity and a more consistent unit

cost.

Factory automation's capabilities are multi-faceted and provide answers to the questions asked of it.

They have been forced to change from basic suppliers of parts, components or equipment to a take

position where they help customers realize greater productivity, quality and a competitive edge from

OEM purchases.

Because there are fewer mechanical components, the OEM can deliver the press at a lower initial

cost to the printer or publisher.

While increased productivity is the clarion call for the OEM, end users must contend with a growing

list of factory automation opportunities, a challenge for implementing successful factory automation.

Among the initiatives that Siemens has started is one called Totally Integrated Power, or TIP, to

better manage energy costs and save money

It can also lead to decreased factory power outages and improve uptime.

As with any powerful technology, consider your risk before you take action.

Make sure you have a solid set of goals and objectives that meet your company's operating needs.

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Context of the Project

Monitoring of the Critical sensor monitoring is very important in several industries (Nuclear plants, power

plants, petroleum and gas). This job should be done with at most accuracy and reliably. The sensor

information should be available at various locations simultaneously to take accurate decisions. This kind of

requirement can be met by using the central servers and connecting the sensor networks through the

controllers to the central servers. Most of the systems require features which are given by web server kind of

architecture on wireless.

Authentication (of the person commanding).

Port numbers for each connecting application.

But the deployment of the web server is costly and complex to maintain.

Maintaining the wireless network has issues.

GSM network is readily available wireless secured network.

PROJECT SURVEY

EXISTING TECHNOLOGIES

Majority of the companies in INDIA have not implemented Automation practices in industry. Except few

large industries majority of the companies cannot afford to invest huge amount of money in the existing

costly setups to meet the requirements of Industrial Automation.

Existing methods widely use the following technologies to communicate the information from one end to

the other end of the company.

Using Bluetooth -- But it is limited to short range.

Using Zigbee/ IEEE802.15.4 -- Range is up to only few Kms maximum.

Using Wi-Fi -- Requires costly equipment setup and high power consumption.

All the methods discussed above are quite expensive and complex to implement and not very reliable. The

availability of information at various nodes simultaneously is not achieved.

Bluetooth Technology

Bluetooth Technology is a radio frequency (RF)-based, short-range connectivity technology that promises to

change the face of computing and wireless communication. It is designed to be an inexpensive, wireless

networking system for all classes of portable devices. The projected cost of the Radio chip was around $5.

A complete Bluetooth system will require these elements:

An RF portion for receiving and transmitting data includes short-range radio transceiver, an

external antenna, and a clock reference (required for synchronization)

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http://www.engineersgarage.com/articles/bluetooth-technology

A module with a baseband microprocessor.

Memory

An interface to the host device (such as a mobile phone.

Its normal range of operation is 10m (at 1mW transmit power) and can be increased up to 100m by

increasing the transmit power to 100mW. The system operate in unlicensed 2.4 GHz frequency band, hence

it can be used worldwide without any licensing issues. It provides an aggregate bit rate of approximately

1Mbps.

Zigbee Technology

The Zigbee radio specification designed for low cost and power consumption than Bluetooth. The

specification is based on IEEE 802.15.4 standard. The radio operates in the same ISM band as Bluetooth and

is capable of connecting 255 devices per network. The specification supports data rates of up to 250Kbps at

a range of up to 30m. These data rates are slower than Bluetooth, but in exchange the radio consumes

significantly with low power with a large transmission range. The goal of Zigbee is to provide radio

operation for months or years without recharging, thereby targeting applications such as sensor networks

and inventory tags.

Wi-Fi Technology

Wi-Fi is the name given by the Wi-Fi Alliance to the IEEE 802.11 suite of standards. 802.11 defined the

initial standard for wireless local area networks (WLANs).

But because of its costly equipment setup and high power consumption this technology is not preferred.

PROPOSED TECHNOLOGY

WHAT IS GSM TECHNOLOGY?

The GSM network that is run by China Mobile Communication Corp. provides reliable communication

quality with nationwide coverage. Short message service (SMS) that is ideal for intermittent small packet

data transmission has now become the most widely used value added service based upon GSM standard.

Meanwhile, the decreasing cost of GSM network devices such as mobile phones and GSM module has made

them an attractive option for other wireless communication applications. By utilizing GSM SMS and

assigning a unique address (SIM card number) to each remote control unit, data and commands can be

transmitted in the wireless communication network. This paper presents design and implementation of a

distributed monitoring and centralized controlling system for prefabricated substations. The system

completely meets the demand of low cost and high level automation by introducing the microprocessor

based RTUs and mobile communication technology.

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http://www.engineersgarage.com/articles/what-is-zigbee-technology

GPRS supports world’s leading packet based internet protocols that makes highly efficient use of radio

spectrum and enables high data speed. It enables any exiting IP or X.25 application to operate over a GSM

cellular connection. Its data speed varies from 115Kbps to 117Kbps but it is likely to average at 56Kbps.

It was developed to enable GSM operators to meet the following key features:

It is a step towards 3G.

Higher bandwidth and therefore data speed.

Seamless, immediate and continues connection to the internet—‘always on-line’.

New text and visual data content services.

Packet switched rather than circuit switched which enable higher radio spectrum efficiency.

Fig: 1 General architecture of GSM network.

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http://www.engineersgarage.com/articles/what-is-3g-technology-specifications

SYSTEM BLOCK DIAGRAM

Fig: 2

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COMPONENTS REQUIED

TOOLS USED

Table-1

Sl no. Tools No.

1. Power Supply 1

2. Relay Driver Circuit 1

3. Biasing Circuit 1

4. Keypad 2

5. Sensor Module 3

HARWARE USED

Micro-controller-AT89S51:

AT 89S51 IS THE MICROCONTROLLER. IT IS THE BRAIN OF MY PROJECT. The device is

manufactured using Atmel’s high-density nonvolatile memory technology and is compatible with the

industry- standard 8051 instruction set and pin out. The on-chip Flash allows the program memory to be

reprogrammed in-system or by a conventional nonvolatile memory programmer. By combining a versatile 8-

bit CPU with in-system programmable Flash on a monolithic chip, the Atmel AT89S51 is a powerful

microcontroller which provides a highly-flexible and cost-effective solution to many embedded control

applications. The AT89S51 provides the following standard features: 8K bytes of Flash, 256 bytes of RAM,

32 I/O lines, Watchdog timer, two data pointers, three 16-bit timer/counters, a six-vector two-level interrupt

architecture, a full duplex serial port, on-chip oscillator, and clock circuitry.

The AT89S51 is a low-power, high-performance CMOS 8-bit microcontroller with 8K bytes of in-system

programmable Flash memory. The device is manufactured using Atmel’s high-density nonvolatile memory

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technology and is compatible with the industry- standard 80S51 instruction set and pin out. The on-chip

Flash allows the program memory to be reprogrammed in-system or by a conventional nonvolatile memory

programmer. By combining a versatile 8-bit CPU with in-system programmable Flash on a monolithic chip,

the Atmel AT89S51 is a powerful microcontroller which provides a highly-flexible and cost-effective

solution to many embedded control applications. The AT89S51 provides the following standard features: 8K

bytes of Flash, 256 bytes of RAM, 32 I/O lines, Watchdog timer, two data pointers, three 16-bit

timer/counters, a six-vector two-level interrupt architecture, a full duplex serial port, on-chip oscillator, and

clock circuitry. In addition, the AT89S51 is designed with static logic for operation down to zero frequency

and supports two software selectable power saving modes. The Idle Mode stops the CPU while allowing the

RAM, timer/counters, serial port, and interrupt system to continue functioning. The Power-down mode

saves the RAM contents but freezes the oscillator, disabling all other chip functions until the next interrupt

or hardware reset.

LCD

One of the most common devices attached to an 8051 is an LCD display. Some of the most common LCDs

connected to the 8051 are 16x2 and 20x2 displays. This means 16.16 characters per line by 2 lines and 20

characters per line by 2 lines, respectively. In recent years the LCD is finding widespread use replacing

LED’s. This is due to the following reasons

Declining prices

Ability to display numbers, characters and graphics.

Incorporation of a refreshing controller into the LCD.

Ease of programming.

Fortunately, a very popular standard exists which allows us to communicate with the vast majority of LCDs

regardless of their manufacturer. The standard is referd to as HD44780U, which refers to the controller chip

which receives data from an external source (in this case, the 8051) and communicates directly with the

LCD. The 44780 standard requires 3 control lines as well as either 4 or 8 I/O lines for the data bus. The user

may select whether the LCD is to operate with a 4-bit data bus or an 8-bit data bus. If a 4-bit data bus is used

the LCD will require a total of 7 data lines (3 control lines plus the 4 lines for the data bus). If an 8-bit data

bus is used the LCD will require a total of 11

The most commonly used Character based LCDs are based on Hitachi's HD44780 controller or other which

are compatible with HD44580. In this tutorial, we will discuss about character based LCDs, their interfacing

with various microcontrollers, various interfaces (8-bit/4-bit), programming, special stuff and tricks you can

do with these simple looking LCDs which can give a new look to your application.

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An LCD display is specifically manufactured to be used with microcontrollers, which means that it cannot

be activated by standard IC circuits. It is used for displaying different messages on a miniature liquid crystal

display

The model described here is for its low price and great capabilities most frequently used in practice. It can

display messages in two lines with 16 characters each. It displays all the letters of English alphabet, Greek

letters, punctuation marks, mathematical symbols etc. In addition, it is possible to display symbols made up

by the user. Other useful features include automatic message shift (left and right), cursor appearance, LED

backlight etc. An LCD screen consists of two lines each containing 16 characters. Each character consists of

5x7 dot matrix.

GSM MODEM

A GSM modem is a specialized type of modem, which accepts a SIM card, and operates over a subscription

to a mobile operator, just like a mobile phone. From the mobile operator perspective, a GSM modem looks

just like a mobile phone. A GSM modem can be a dedicated modem device with a serial, USB or Bluetooth

connection, or it may be a mobile phone that provides GSM modem capabilities. A GSM modem could also

be a standard GSM mobile phone with the appropriate cable and software driver to connect to a serial port or

USB port on computer. Any phone that supports the "extended AT command set" for sending/receiving

SMS messages, as defined in the ETSI GSM 07.05 Specification can be supported by the Now SMS/MMS

Gateway. In the proposed system we have used SIMCOM SIM300 GSM module.

SIM300 is a Tri-band GSM/GPRS engine that works on frequencies EGSM 900 MHz, DCS 1800 MHz and

PCS1900MHz. SIM300 provides GPRS multi-slot class 10 capability and support the GPRS coding schemes

CS-1, CS-2, CS-3 and CS-4.With a tiny configuration of 40mm x 33mm x 2.85 mm , SIM300 can fit almost

all the space requirement in your application, such as Smartphone, PDA phone and other mobile device.

The physical interface to the mobile application is made through a 60 pins board-to-board connector, which

provides all hardware interfaces between the module and customers boards. The SIM300 is designed with

power saving technique, the current consumption to as low as 2.5mA in SLEEP mode. The SIM300 is

integrated with the TCP/IP protocol, Extended TCP/IP AT commands are developed for customers to use

the TCP/IP protocol easily, which is very useful for those data transfer applications.

MAX 232 Level Converters

Since the RS232 is not compatible with today’s Microprocessors and Microcontrollers, we need a line driver

or voltage converter to convert RS232‟s signals to TTL voltage levels. One example of such a converter is

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MAX 232 from Maxim corp. The MAX232 converter converts from RS232 voltage levels to TTL voltage

levels and vice versa. One advantage of the MAX232 chip is that it uses a +5v power source, which is the

same as the source voltage for the microcontroller. In other words, with a single +5v power supply we can

power both the microcontroller and MAX232, with no need for the dual power supplies that are common in

many older systems. The MAX 232 has two sets of line drivers for transferring and receiving data.

DEVLOPMENT ENVIROMENT :-

The following software development tools we used to develop this project

Keil Microvision.2

Topwin

Orcad 9.2

Keil Microvision.2

This Software is basically used for writing Assembly Language programming.

8051 Embedded C kit provides Keil uvision3 evaluation version along with the kit. This is an IDE

that combines project management, make facilities, source code editing, program debugging and complete

simulation under one powerful environment. u vision includes traditional features like simple and complex

breakpoints, watch windows and execution control as well as sophisticated features like trace capture,

execution profiler, code coverage and logic analyzer. The µVision Debugger provides a number of ways to

display variables and program objects.

What is an Assembler?

An assembler is a software tool designed to simplify the task of writing computer Programs. It translates

symbolic code into executable object code. This object code may then be programmed into a microcontroller

and executed. Assembly language programs translate directly into CPU instructions which instruct the

processor what operations to perform. Therefore, to effectively write assembly programs, you should be

familiar with both the microcomputer architecture and the assembly language.

TOP win

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This software is generally used for writing the HEX file into the Microcontroller. So that the Microcontroller

can work according to the user definable programming.

Fig: 3

Orcad 9.2

This is another type one that is specially used to draw the Hardware Circuit Diagram for the development of

any project. ORCAD is a suite of tools cadence for the design and layout of printed circuit board (PCBs).

This tutorial covers version 9.2 of the ORCAD suite. This document will give you a crash course in

designing an entire circuit from start to finish. This is very small and simple circuit, but it will demonstrate

the major concepts and introduce the tools behind completing a PCB design. After you have completed the

tutorial, you will know all the steps needed to make PCBs using ORCAD. This is not, however, a guide to

the inner working of the ORCAD interface. You should use this document in conjuction with the online

RCADnd tutorial.

What is Microcontroller?

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Microcontroller is a 8 bit processer meaning that the central processing unit can work on only 8 bits of data

at a time. 4K (4096) BYTES of on-chip ROM (program memory). 128 bytes of on-chip RAM (THAT IS

DATA MEMORY). Two timers, one serial port and 4 ports each of 8 bits wide all available in a single

chip.8051 Microcontroller has 4 register bank (bank0, bank1, bank2, bank3. Two multiple code, 16 bit

timer/counters are used.1 microsecond instruction cycle with 12 MHZ crystals are used. It has direct byte

and bit addressability. It is available with 40 pins IC and DIP.

8051 microcontroller has only one data type 8 bits. Size of each register is also 8 bits. It is the job of the

programmer to break down data larger than 8 bits (00H TO FFH or 0 to 255 in decimal). The data type can

be positive or can be negative.

It has the properties of bit address. Many microprocessors allow the program to access register and I/O port

in byte size only. But in many applications we have to check a single bit. One unique and power full

operation of 8051 microcontroller is single bit operation. Single bit operation allows the programmer to set,

clear, move and compliment individual bit of a port, memory, or register.

Fig: 4

It is registers, RAM, and I/O ports that need to be bit-addressable. ROM, holding program code for

execution, is not bit addressable.

It has four ports each of 8 bits P0, P1, P2 and P3.The AT89C51 has 4K bytes of programmable flash. The

port P0 covers the pin 32 to pin 39, the port P1 covers the pin 1 to pin 8, the port P2 covers the pin 21 to pin

28 and the port P3 covers the pin 10 to pin 17. Pin 9 is the reset pin. The reset is active high. Whenever the

controller is given supply, the reset pin must be given a high signal to reset the controller and bring the

program counter to the starting address 0x0000. The controller can be reset by manually connecting a switch

or by connecting a combination of resistor and capacitor as shown in the circuit diagram. A 12 MHz crystal

is connected between pin 18 pin 19. Pin 40 is VCC and pin 20 is ground. Pin 31, is connected to VCC as we

are using the internal memory of the controller.

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Role of the microcontroller in this project.

Security system

Microcontroller will control the LCD initialization and select the data register and command .

Memory is connected to microcontroller using two pins.

GSM connect through max232 to information passes.

For giving signal to relay buzzer circuit.

Collect information from sensor and give back to the LCD.

Why we should choose Microcontroller why not Microprocessor?

It is very clear from figure that in microprocessor we have to interface additional. Circuitry for providing the

function of memory and ports, for example we have to interface external RAM for data storage, ROM for

program storage, programmable peripheral interface (PPI) 8255 for the Input Output ports, 8253 for timers,

USART for serial port. While in the microcontroller RAM, ROM, I/O ports, timers and serial

communication ports are in built. Because of this it is called as “ system on chip”. So in micro-controller

there is no necessity of additional circuitry which is interfaced in the microprocessor because memory and

input output ports are inbuilt in the microcontroller. Microcontroller gives the satisfactory performance.

Structure of microcontroller

MICROCONTROLLER 8051 ARCHITECTURE:

It is 8-bit microcontroller, means MC 8051 can Read, Write and Process 8 bit data. This is mostly used

microcontroller in the robotics, home appliances like mp3 player, washing machines, electronic iron and

industries. Mostly used blocks in the architecture of 8051 are as follows:

128 Byte RAM for Data Storage.MC 8051 has 128 byte Random Access memory for data storage. Random

access memory is non volatile memory. During execution for storing the data the RAM is used. RAM

consists of the register banks, stack for temporary data storage. It also consists of some special function

Register(SFR) which are used for some specific purpose like timer, input, output ports etc.Normally

microcontroller has 256 byte RAM in which 128 byte is used for user space which is normally register.

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Fig: 5

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PIN DIAGRAM

Fig: 6

Description of each pin is discussed here:

VCC →5V supply

VSS →GND

XTAL2/XTALI are for oscillator input

Port 0 – 32 to 39 – AD0/AD7 and P0.0 to P0.7

Port 1 – 1 to 8 – P1.0 to P1.7

Port 2 – 21 to 28 – P2.0 to P2.7 and A 8 to A15

Port 3 – 10 to 17 – P3.0 to P3.7

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P 3.0 – RXD – Serial data input – SBUF

P 3.1 – TXD – Serial data output – SBUF

P 3.2 – INT0 – External interrupt 0 – TCON 0.1

P 3.3 – INT1 – External interrupt 1 – TCON 0.3

P 3.4 – T0 – External timer 0 input – TMOD • P 3.5 – T1 – External timer 1 input – TMOD

P 3.6 –WR – External memory write cycle – Active LOW

P 3.7 – RD – External memory read cycle – Active LOW

RST – for Restarting 8051

ALE – Address latch enable

1 – Address on AD 0 to AD 7

0 – Data on AD 0 to AD 7

PSEN – Program store enable

TECHNICAL SPECIFICATION:

Voltage - 12V AC/DC

Operating Current – 225 MA

Contact Rating - 230V AC

INTERFACING WITH DIFFERENT MODULES

Interface with GSM

The project explains interfacing of the AT89C51 microcontroller with the GSM MODULE and the

HyperTerminal. HyperTerminal is a Windows application. The AT commands are sent by the

HyperTerminal to the GSM module. The Information Response and/or Result Codes are received at the

microcontroller and retransmitted to the HyperTerminal by the controller.

A GSM module has an RS232 interface for serial communication with an external peripheral. In this case,

the transmit pin (Tx) of the computer’s Serial port is connected with the receive pin (Rx) of the GSM

module’s RS-232 interface. The transmit pin (Tx) of the RS-232 of GSM module is connected to receive pin

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(Rx) of microcontroller’s serial transmission pin. And the serial transmit pin of the microcontroller is

connected to the receive pin of the computer’s Serial port. Therefore the commands and their results are

transmitted and received in a triangular fashion as depicted below.

Fig: 7

[In subsequent projects (see MC075 & MC076), the HyperTerminal will be replaced by the microcontroller

itself; thus avoiding the need of using a Computer to establish an interface. This would lead to an

independent GSM based system.]

The microcontroller is programmed to receive and transmit data at a baud rate of 9600. For more details on

setting the baud rate of microcontroller, refer serial communication with 8051.

The controller can receive data signals either by polling or by making use of serial interrupt (ES). Serial

interrupt has been explained in interrupt programming. In polling, the controller continuously scans serial

port for incoming data from the GSM module.

In this project, interrupt has been used for monitoring and controlling the flow of data by the controller

instead of the polling method.

Interfacing with LED

LEDs is by far the most widely used means of taking output. They find huge application as indicators during

experimentations to check the validity of results at different stages. They are very cheap and easily available

in a variety of shape, size and colors. The principle of operation of LEDs is simple. The commonly available

LEDs have a drop voltage of 1.7 V and need 10 mA to glow at full intensity. The following circuit describes

“how to glow a led”.

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Fig: 8

The value of resistance R can be calculated using the equation, R= (V-1.7)/10 mA. Since most of the

controllers work on 5V, so substituting V= 5V, the value of resistance comes out to be 330 ohm. The

resistance 220 ohm, 470 ohm is commonly used substitute in case 330 ohm is not available. AT89C51 is a

40 pin microcontroller which belongs to 8051 series of microcontroller .LEDs is connected to the port P0.

LEDs need approximately 10mA current to flow through them in order to glow at maximum intensity.

However the output of the controller is not sufficient enough to drive the LEDs, so if the positive leg of the

LED is connected to the pin and the negative to ground as shown in the figure, the LED will not glow at full

illumination.

To overcome this problem LEDs are connected in the reverse order and they run on negative logic i.e.,

whenever 1 is given on any pin of the port, the LED will switch off and when logic 0 is provided the LED

will glow at full intensity.

As soon as we provide supply to the controller, the LEDs start blinking i.e., they become on for a certain

time duration and then become off for the same time duration. This delay is provided by calling the delay

function. The values inside the delay function have been set to provide a delay in multiples of 100

millisecond delays (millisecond).

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Interfacing of LCD: To interface this LCD with microcontroller, two registers (Input and Output register)

are provided in the LCD. These registers are selected by the combination of RS and RW signals.

Fig: 9

Input Register:

Input Register is used while giving instructions and writing data to LCD. It holds the data/instruction

temporarily before writing to DDRAM (Data Display RAM). When the LCD is in active mode (CS1 and

CS2 high), the Input register can be selected by sending bits on RS and RW pins as shown in the following

table. The data of input register is latched in at the falling edge (from high to low) of EN (Enable) signal and

written into DDRAM automatically through internal operation.

Output Register:

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Output Register is used to read data from DDRAM and to check status data (busy check). When the LCD is

in active mode (CS1 and CS2 high), the Output register can be selected by sending bits on RS and RW pins

as shown in the following table. When R/W and RS are high, data is latched into output register and when

R/W=H, RS=L, status data (busy check) can be read out.

R/W RS Function

LL Send Instruction

H Data Write (From Input Register to DDRAM)

HL Status Check (Busy Read)

H Data Read (From DDRAM to Output Register)

Table-2

The basic operation with graphical LCD requires following steps:

1. LCD Initialization

2. Page Selection

3. Column Selection

4. Data Display

All these steps have been explained in the following sections with corresponding instruction sets.

Ckt diagram of the LCD interfaced

Fig: 10

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LCD Initialization

Before displaying anything on graphics LCD, it must be initialized, i.e., display must be put on and

column/page selection be made. This is achieved by giving proper instructions to the LCD. To make Display

On\Off the following set of instructions must be followed in order:

a) Put these values in Data Register

DB7 DB6 DB5 DB4 DB3 DB2 DB1 DB0

0 0 1 1 1 1 1 D

Table-3

Data appears when D=1 and disappears when D=0. When the display is off, there is no effect on the data

which is stored in DDRAM.

b) CS1=1,CS2=1(to activate display of both halves of LCD)

c) RS=0, R/W=0 (to select the instruction mode)

d) EN=1

e) Delay

f) EN=0 (to latch data into the input register)

Display on/off function can also be used to blink data continuously on the LCD by switching the display

with some delay.

2. Page selection

Before writing any data, the page of LCD must be selected. Page can be selected through following steps:



1 0 1 1 1 X3 X2 X1

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Table-4

Since there are a total of 8 pages (0–7), a particular page is selected by setting three bits (X1-X3).

b) CS1=1, CS2=1(to activate display of both halves of LCD)

c) RS=0, R/W=0 (to select the instruction mode)

d) EN=1

e) Delay


For example, if X3=0, X2=1 and X1=0, then the second page is selected. Reading or writing operation is

done on this page until next page is set. Depending on the column selection, the page is selected from either

left or right half of the graphics LCD.

3. Column selection

There are 128 [64 (=26) columns per half] in graphics LCD and they are automatically incremented. This

means that after selecting a column, it increases on its own by one, after each write cycle. So it is easier to

write data column by column. A column can be chosen through following instructions:



0 1 Y5 Y4 Y3 Y2 Y1 Y0

Table-5

The corresponding controller (CS1 or CS2) is selected depending on the Column number as shown below.

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Fig: 11

b) RS=0, R/W=0 (to select the instruction mode)

c) EN=1

d) Delay

e) EN=0 (to latch data into the input register)

For example, if Page address is 0 and Column address is 0, then 0th column of page 0 is selected, i.e., the

first pixel will be selected which is highlighted in the following diagram.

4) Display data

After page and column selection, data can be sent to LCD for display. The programming steps for display

data are as given below:

a) Put the data values in Data Register. With every write cycle, data is written in one column and the

column then gets auto-incremented. A high data bit (DBx = 1) corresponds to activated (dark) pixel and low

data bit (DBx = 0) corresponds to deactivated (light) pixel. Here MSB corresponds to 8th row in column and

LSB to 1st row of column.

b) If column<63 then (CS1=1 & CS2=0) else (CS1=0 & CS2=1)

c) RS=1 and R/W=0 (to select write mode of LCD)

d) EN=1

e) Delay


If data port is given value ‘0x99’ or ‘10011001’ then column takes the values as shown below.

The following points can be included in above programming steps for efficient programming:

1. While sending data to be written with array, one can specify the array limit as well. This limit

signifies the number of columns one wants to write at once. If the limit is 8, eight columns will be written at

once and if it is 7, seven columns will be written in one go.

2. The condition ‘if (column >127)’ can be used to return the control back to the main function if the

limit exceeds the number of columns present in the LCD.

3. The function for setting column should be called again if array limit condition doesn’t fit in left page

and has to be extended to right page too.

23

4. Though column address increases itself by one but one variable should be taken to check the

conditions (ii) & (iii) explained above.

To use above functions, a simple experiment can be done to display alphabetic characters in different fonts.

Here, the alphabet ‘A’ is being displayed in different fonts. These shapes can be displayed by using their

corresponding bitmap values shown in the above diagram. The connection of graphical LCD with AT89C52

is shown in circuit diagram. Also learn to display text/string and display image on Graphics LCD.

Interfacing of memories:

EEPROM stands for electrically erasable programmable read only memory. It is a secondary storage device

that once written (programmed) can hold data even when the power is removed. The EEPROM is a class of

read only memory that can be electrically erased and reprogrammed.

AT24C02 is a two wire 2Kbits serial EEPROM by Atmel. The memory is organized in 256 words of single

byte each arranged in 32 pages of 8 bytes each. The addressing of memory locations requires eight bit

addresses.

AT24C02 is two-wire serially programmable i.e., for programming, the data and control signals are provided

serially along with clock signals from the other wire. The read-write operations are accomplished by sending

a set of control signals including the address and/or data bits. The control signals must be accompanied with

proper clock signals.

The AT24C02 has hard wire addressing of 3 bit length. This facilitates interfacing of a maximum of eight

(23) 24C02 devices to a system thereby, incorporating a maximum 16Kbits memory. Multiple 24C02

devices can be connected to a microcontroller/microprocessor based system using I2C interface. The project

demonstrates interfacing of a single 24C02 IC with AT89C51 (8051) microcontroller. Simple analog

communication over the telephone wires to the typical USB cables for data exchange, we surely have come

a long way in the field of communication. RS232 was the first milestone reached in this journey. It was a

standard for electromechanical typewriters and modems for digital data exchange introduced in 1962 by the

Radio Sector of EIA. It made the data exchange more reliable over analog channel. The standard defined

voltage levels that made it immune to noise disturbances and reduced the error in data exchange. As the

technology was growing many electronic devices were being developed during this time like computers,

printers, test instrument etc. There came a time where manufacturers felt the need to exchange information

between these electronic devices. For example data exchange between a computer and a printer or two

computers. But there was no standard or method to accomplish this task. RS232 was the only available

standard at the time which was used for data exchange. So, they thought of adopting this standard in

electronic devices for digital communication

24

DC OutputAC Power

AC/DC Adapter

Regulator (7805)

Filter

Memory

An interface to the host device (such as a mobile phone).Its normal range of operation is 10m (at 1mW

transmit power) and can be increased up to 100m by increasing the transmit power to 100mW. The system

operate in unlicensed 2.4 GHz frequency band, hence it can be used worldwide without any licensing issues.

It provides an aggregate bit rate of approximately 1Mbps.

These memory devices are used to store the data for off line process. The AT24C02A provides 2048bits of

serial electrically erasable and programmable read only memory (EEPROM) organized as 256words of 8

bits each. The device is optimized for use in many industrial and commercial applications where low power

and low voltage operation are essential. The AT24C02A is available in space saving 8-pin PDIP.

POWER SUPPLY

The microcontroller and other devices get power supply from AC to Dc adapter through 7805, 5 volts

regulator. The adapter output voltage will be 12V DC non-regulated. The 7805/7812 voltage regulators are

used to convert 12 V to 5V/12V DC.

Fig: 12

REGULATED POWER SUPPLY :

230

AC

I/PTransformer Rectifier smoothing regulator

REGULATED

5V

Fig: 13

25

Components of Power Supply:

SI NO COMPONENTS USED TYPE NOS USED

1. Transformer 230V AC,RATING-18 V,1 AMP 1

2. Rectifier Bridge Rectifier 1

3. Capacitor Electrolytic 2

4. Voltage Regulator 7805 , 7812 2

5. Resistor 1

Table-6

Function of each block is described in more detail below:

1-Transformer steps down high voltage AC mains tow low voltage AC.

2-Rectifier converts AC to DC, but the DC output is varying.

3-Smoothing smoothes the D C from varying greatly to a small ripple.

4-Regulator eliminates ripple by setting DC output to fixed voltage.

Fig: 14

26

VITAL ROLE OF POWER SUPPLY IN ‘GSM BASED MANUFACTURING INDUSTRIAL AUTOMATION PROJECT’

The adapter output voltage will be 12V DC non-regulated. The 7805/7812 voltage regulators are

used to convert 12 V to 5V/12V DC.

Fig: 15

Breaking this system down , we will first look at the ac voltage change and ac to dc

conversion. Then, we will look at some simple dc regulation circuitry.

TRANSFORMER

Transformer steps down high voltage AC (230 v ac) mains to low voltage AC.(18 v ac)

Transformer rating is 18v,1 AMP

In a rectifier, a center -tapped transformer and two diodes can form a full-wave rectifier that allows

both half-cycles of the AC waveform to contribute to the direct current, making it smoother than

a half-wave rectifier.

Center-tapped transformers are also used for dual-voltage power supplies.

Center tapped transformer is used when the output DC current is high and the output voltage is

low. Center tap is a connection made to a point halfway along a winding of a transformer.

Center-tapped transformers are also used for dual-voltage power supplies. When a center-tapped transformer

is combined with a bridge (four diode) rectifier, it is possible to produce a positive and a negative voltage

with respect to a ground at the tap. Dual voltage supplies are important for all sorts of electronics equipment.

27

Fig: 16

Fig: 17

RECTIFIER

A rectifier is an electrical device that converts AC which periodically reverses direction to DC which flows

in only one direction .Here, we have used bridge rectifier since low voltage AC (output of transformer) is

not suitable for electronic circuit unless they include a rectifier and smoothing capacitor. Bridge rectifier

produces full wave varying DC.A full wave rectifier can also be made from just two diodes if centre tapped

transformer is used, but it is available in special packages containing the four diodes required. It is called a

full wave rectifier because it uses the entire AC wave (both positive and negative section). 1.4 volt is used

up in the bridge rectifier because each diode uses 0.7 volt when conducting and there are always two diode

conducting. The maximum current they can pass rates bridge rectifiers and the maximum reverse voltage

they can withstand (this must be at least three times the supply RMS voltage so the rectifier can withstand

the peak voltages).

28

Fig: 18

ELECTROLYTE CAPACITOR (SMOOTHING UNIT)

Capacitors are used in power supply filter networks. The capacitors smooth out the “bumpy” AC to DC.

Smoothing is performed by a large value electrolyte capacitor connected across the DC supply to act as a

reservoir, supplying current to the output when the varying dc voltage from the rectifier is falling. The

diagram shows the unsmoothed varying dc and the smoothed DC. The capacitor charges quickly near the

peak of the varying DC, and then discharges as it supplies current to the output.

Smoothing capacitor for 10% ripple, C= 5 * Io/Vs * f

C=smoothing capacitor in farads (F)

Io=output current from the supply in amps (A)

Vs=supply voltage in volts, this is peak value of the unsmoothed DC

f = frequency of AC supply in hertz

29

Fig: 19

The output from the transformer and rectifiers follows the sin waveform.

The smoothing capacitor ‘fills in’ the low voltage portions, so reducing the ripple voltage amplitude.

The larger the capacitor (for a given load), the smaller the ripple voltage, but the higher the peak current

through the rectifiers.

Fig: 20

VOLTAGE REGULATORS

Because most circuits have been designed to only work with a very specific voltage level – changes could

greatly affect how the circuit works. To ensure that the output voltage of a power supply is always the same

(regardless of the changes of input voltage and Load resistance) a Voltage Regulator is used .It is a

semiconductor device that converts an input DC voltage to a fixed output DC voltage A voltage regulator is

an electrical regulator designed to automatically maintain a constant voltage level .We have used 7805 and

7812 voltage regulators. These two come from 78xx family of self contained fixed linear voltage regulators.

The 78xx line are positive voltage regulators, meaning that they are designed to produce a voltage that is

positive relative to a common ground.

Many of the fixed voltage regulator ICs has 3 leads and look like power transistors, such as 7805 regulator.

They include a hole for attaching a heat sink if necessary. The 7805 IC is designed for a fixed voltage

output of 5V and 7812 IC for a fixed voltage output of 12V.These have built in current limiting, thermal

30

shutdown, and safe operating area protection which makes them virtually immune to damage from output

overloads.

Fig: 21

Fig: 22

31

fig: 23 fig: 24

32

Fig: 25

RELAY MODULE

SI NO COMPONENTS USED TYPE NOS USED

1. Relay Electromechanical relay 1

2. Transistor NPN Transistor 1

3. Diode Freewheeling diode 2

4. Resistor 1

5. Buzzer Piezoelectric Buzzer 1

Table-7

Fig: 26

33

WHAT IS A RELAY?

Relays are electromagnetically operated switches. An actuating current on a coil operates one or more

galvanically separated contacts or load circuits.

HOW A RELAY WORKS?

Fig: 27

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 as shown in the diagram below

Fig : 2834

Relays allow one circuit to switch a second circuit which can be completely separate from the first. For

example a low voltage battery circuit can use a relay to switch a 230V AC mains circuit. There is no

electrical connection inside the relay between the two circuits; the link is magnetic and mechanical.

The coil of a relay passes a relatively large current, typically 30mA for a 12V relay, but it can be as much as

100mA for relays designed to operate from lower voltages. Most ICs (chips) cannot provide this current and

a transistor is usually used to amplify the small IC current to the larger value required for the relay coil. The

maximum output current for the popular 555 timer IC is 200mA so these devices can supply relay coils

directly without amplification. Relays are usually SPDT or DPDT but they can have many more sets of

switch contacts, for example relays with 4 sets of changeover contacts are readily available.

Fig : 29

The animated picture shows a working relay with its coil and switch contacts. You can see a lever on the left

being attracted by magnetism when the coil is switched on. This lever moves the switch contacts. There is

one set of contacts (SPDT) in the foreground and another behind them, making the relay DPDT.

ELECTROMECHANICAL RELAY

The electromechanical relay is a remote controlled switch capable of switching multiple circuits either

individually , simultaneously or in sequence. In this relay the switching element is a mechanical contact

actuated by an electromagnet.

The principal internal function of the electromechanical relay are:

i. Conversion of electrical current to a magnetic field.

ii. Conversion of the magnetic field into a mechanical force.

iii. This force operates the contact.

iv. Contacts switch and conduct electrical current.35

Fig : 30

RELAY DRIVER CIRCUIT

The relay operates at 12V and the microcontroller operates at 5V.when the coil energization is switched

off ,a very high negative peak voltage is produced by the coil and it may reach more than 10-20 times the

nominal coil voltage. And this cuurent will reach the microcontroller and cause damage to it. Inorder to

protect the microcontroller from damage ,a relay driver circuit is provided.The main function of the relay

driver circuit is to provide necessary current to the microcontroller and to energize the relay coil.

MCU CAN NOT DIRECTLY DRIVE RELAYS. SO WE NEED DRIVER CIRCUIT.

DRIVER CIRCUIT IS USED TO DRIVE 4 CHANNEL RELAY.

BC 547 IS USED IN DRIVER CIRCUIT.

IF THE TRANSISTOR CONDUCTS THEN IT WILL OPERATE THE RELAY.

THE TRANSISTOR WILL CONDUCT DEPENDS UPON THE MICROCONTROLLER

SIGNAL.

Fig : 31

36

WE ARE USING 4 NOS. OF SPDT RELAYS

o IT HAS 5 PIN.

o IT WILL OPERATE ON 12V DC.

o THE MAIN USE OF RELAY SECTION IS TO CONTROL 230 V AC.

CIRCUIT DIAGRAM

Fig : 32

FLYWHEEL DIODES

Normally DC relays are operated through semiconductor devices. due to the inductance of the coil ,high

voltage peaks are induced9in the form of back emf) when the coil supply is switched off.

To protect the relay control transistors against this surge voltage, protection in the form of flywheel diodes

is provided. The diodes are connected parallel to the coil in reverse polarity to the coil supply. While

discharging the back emf flywheel diode provides a low resistance path protecting the driving circuit.

The back emf dies gradually by forming loops.

37

NPN TRANSISTOR

Here the transistor operates as a switch .To operate the transistor as a switch ,the transistor needs to be

turned either fully ‘OFF’(cut off) or fully ‘ON’(saturated).In practise ,when the transistor is turned ‘OFF’

small leakage current flow through the transistor and when fully ‘ON’ the device has a low resistance value

causing a small saturation voltage(VCE) across it.

Fig : 33

In order the base current to flow, the base input terminal must be made more positive than the emitter by

increasing it above 0.7 volts needed for a silicon device. By varying this base emitter voltage VBE, the base

current is also altered and which in turn controls the amount of collector current flowing through the

transistor. When maximum collector current flows the transistor is said to be saturated. The value of the

base resistor determines how much input voltage is required and corresponding base current to switch the

transistor fully ‘ON’. The transistor is driven into saturation(turned on) when a logic 1 is written on the port

pin thus turning ON the relay.

RESISTORS

When relays are controlled by semiconductor such as transistors, they require some type of voltage

suppression device .Solid state circuits are vulnerable to voltage spikes. Voltage spikes slam against

transistor destroying them. High ohm resistors are used instead of diodes. A resistor is more durable than a

diode and can suppress voltage spikes similar to a diode but the resistor will allow current to flow through it

whenever the relay is ON. Therefore, the resistance of the resistor must be fairly high inorder to prevent too

much current flow in the circuit.

PIEZOELECTRIC BUZZER

We have used a piezoelectric buzzer in our project. Early devices were based on an electromechanical

system identical to an electric bell without the metal gong. Similarly, a relay may be connected to interrupt 38

http://en.wikipedia.org/wiki/Relay

http://en.wikipedia.org/wiki/Electric_bell

its own actuating current, causing the contacts to buzz. Often these units were anchored to a wall or ceiling

to use it as a sounding board. The word "buzzer" comes from the rasping noise that electromechanical

buzzers made. Here we use this mechanical buzzer for the information that the password is wrong. The

buzzer gives the sound only when the password is typed three times in the wrong way.

WORKING OF A PIEZOELECTRIC BUZZER

When a small DC voltage is applied to the input pins, it is first connected to an oscillating signal using the

combination of resistor and transistor. These oscillating signals are amplified using the inductor coil. When

the high voltage alternating signals are applied to the piezoelectric ceramic disc ,it causes mechanical

expansion and contraction in radial direction. This causes the metal plate to bend in opposite direction.

When metal plate bends and shrinks in opposite direction continuously it produces sound waves in the air.

Fig :33

This is the opposite side of the PCB having the necessary electronic components: :resistor, a transistor and

an inductor. The input to the transistor is a low voltage DC signal, however inorder to produce sound the

piezoceramic disc needs oscillations of high voltage.

The transistor and resistor combination works as an oscillator circuit to produce low amplitude oscillations

from the DC voltage .The magnitude of these oscillation is

amplified by the inductor.

39

http://en.wikipedia.org/wiki/Switch

http://en.wikipedia.org/wiki/Electric_current

Fig:35

.

The red lead is connected to the input the black lead is connected to ground.

.

KEYPAD

We are using 8 keypad push button switches. This section is connected to P1 of Microcontroller. This

section is the INPUT device, which is used for giving password to devices. Here we are using 8 serial keys

to microcontroller.

Fig :36

LCD(LIQUID CRYSTAL DISPLAY)

One of the most common devices attached to an 8051 is an LCD display. Some of the most common LCDs

connected to the 8051 are 16x2 and 20x2 displays. This means 16.16 characters per line by 2 lines and 20

characters per line by 2 lines, respectively. In recent years the LCD is finding widespread use replacing

LED’s. This is due to the following reasons

40

1. Declining prices

2. Ability to display numbers, characters and graphics.

3. Incorporation of a refreshing controller into the LCD.

4. Ease of programming.

Fortunately, a very popular standard exists which allows us to communicate with the vast majority of LCDs

regardless of their manufacturer. The standard is referred to as HD44780U, which refers to the controller

chip which receives data from an external source (in this case, the 8051) and communicates directly with the

LCD. The 44780 standard requires 3 control lines as well as either 4 or 8 I/O lines for the data bus. The user

may select whether the LCD is to operate with a 4-bit data bus or an 8-bit data bus. If a 4-bit data bus is used

the LCD will require a total of 7 data lines (3 control lines plus the 4 lines for the data bus). If an 8-bit data

bus is used the LCD will require a total of 11.

The most commonly used Character based LCDs are based on Hitachi's HD44780 controller or other which

are compatible with HD44580. In this tutorial, we will discuss about character based LCDs, their interfacing

with various microcontrollers, various interfaces (8-bit/4-bit), programming, special stuff and tricks you can

do with these simple looking LCDs which can give a new look to your application.

An LCD display is specifically manufactured to be used with microcontrollers, which means that it cannot

be activated by standard IC circuits. It is used for displaying different messages on a miniature liquid crystal

display.

The model described here is for its low price and great capabilities most frequently used in practice. It can

display messages in two lines with 16 characters each. It displays all the letters of English alphabet, Greek

letters, punctuation marks, mathematical symbols etc. In addition, it is possible to display symbols made up

by the user. Other useful features include automatic message shift (left and right), cursor appearance, LED

backlight etc. An LCD screen consists of two lines each containing 16 characters. Each character consists of

5x7 dot matrix.

PIN DESCRIPTION

The most commonly used LCDs found in the market today are 1 Line, 2 Line or 4 Line LCDs which have

only 1 controller and support at most of 80 characters, whereas LCDs supporting more than 80 characters

make use of 2 HD44780 controllers. Most LCDs with 1 controller has 14 Pins and LCDs with 2 controller

has 16 Pins (two pins are extra in both for back-light LED connections). Pin description is shown in the table

below.

Pin No. Name Description

41

Pin no. 1 D7 Data bus line 7 (MSB)

Pin no. 2 D6 Data bus line 6






Pin no. 8 D0 Data bus line 0 (LSB)

Pin no. 9 EN1 Enable signal for row 0 and 1 (1stcontroller)

Pin no. 10 R/W 0 = Write to LCD module1 = Read from LCD module

Pin no. 11 RS 0 = Instruction input1 = Data input

Pin no. 12 VEE Contrast adjust

Pin no. 13 VSS Power supply (GND)

Pin no. 14 VCC Power supply (+5V)

Pin no. 15 EN2 Enable signal for row 2 and 3 (2ndcontroller)

Pin no. 16 NC Not Connected

Table-8

Enable

The EN line is called "Enable." This control line is used to tell the LCD that you are sending it data. To send

data to the LCD, your program should make sure this line is low (0) and then set the other two control lines

and/or put data on the data bus. When the other lines are completely ready, bring EN high (1) and wait for

the minimum amount of time required by the LCD datasheet (this varies from LCD to LCD), and end by

bringing it low (0) again.

Register select

The RS line is the "Register Select" line. When RS is low (0), the data is to be treated as a command or

special instruction (such as clear screen, position cursor, etc.). When RS is high (1), the data being sent is

text data which should be displayed on the screen. For example, to display the letter "T" on the screen you

would set RS high.

42

Read/Write(R/W)

The RW line is the "Read/Write" control line. When RW is low (0), the information on the data bus is being

written to the LCD. When RW is high (1), the program is effectively querying (or reading) the LCD. Only

one instruction ("Get LCD status") is a read command. All others are write commands--so RW will almost

always be low.

Finally, the data bus consists of 4 or 8 lines (depending on the mode of operation selected by the user). In

the case of an 8-bit data bus, the lines are referred to as DB0, DB1, DB2, DB3, DB4, DB5, DB6, and DB7.

Above is the quite simple schematic. The LCD panel's Enable and Register Select is connected to the

Control Port. The Control Port is an open collector / open drain output.

Fig :37

Connecting an LCD to a micro controller is very simple, requiring either bit or an 8-bit bus. A 4-bit interface

saves I/O pins but requires that the command and data be split into 4-bit pieces, which are sent one after the

other. Thus the saving in I/O lines comes at the price of more complicated software. To simplify

understanding of the software the example uses a 8-bit interface. Three control lines are required in addition

to the data line.

The voltage at the V0 pin adjusts the contrast of the display. Normally this voltage is provided by an

adjustable voltage divider.

CIRCUIT DIAGRAM

43

Fig :38

WORKING AND PRODUCT COUNT

In working and production count three sensors module are used.

SL.NO COMPONENTS NO.

1 IR LED 1

2 Photo transistor 1

3 Variable resistor 1

4 555 timer 1

5 Resistor

6 Capacitor

Table-9

SENSOR MODULE

44

Light Sensor (worker count):

We are using two sensor modules, used for counting numbers of worker of the industry.

LDRs or Light Dependent Resistors are very useful especially in light/dark sensor circuits. Normally the

resistance of an LDR is very high, sometimes as high as 1000 000 ohms, but when they are illuminated with

light resistance drops dramatically.

A Light Dependent Resistor ( LDR, photoconductor, or photocell) is a device which has a resistance

which varies according to the amount of light falling on its surface.

Fig :39

A typical light dependent resistor is pictured above together with (on the right hand side) its circuit diagram

symbol. Different LDR's have different specifications, however the LDR 's we sell in the REUK Shop are

fairly standard and have a resistance in total darkness of 1 MOhm, and a resistance of a couple of k Ohm in

bright light (10-20kOhm @ 10 lux, 2-4kOhm @ 100 lux).

On this section we are controlling Relay by LDR sensor.

If anybody pass across the sensor then it will change the resistance up to 6k ohm. And this change resistance

will give proper base voltage to Darlington transistor. And the output of this biasing circuit is connected to

the relay. If the biasing circuit conduction then relay became operate, which cause a low pulse to

microcontroller.

IR Sensor (product count):

For the counting of the product in the factory ewe use the sensor named TSOP 1738.

45

Fig :40

The TSOP1738 – series are miniaturized receivers for infrared remote control systems. PIN diode and

preamplifier are assembled on lead frame, the epoxy package is designed as IR filter. The demodulated

output signal can directly bedecoded by a microprocessor. TSOP17 is thestandard IR remote control receiver

series, supportingall major transmission codes.The ultimate utilisation of the sensor is to count the finished

product produced and carried by the conveyor here

IR LED:

An IR LED, also known as IR transmitter, is a special purpose LED that transmits infrared rays in the range

of 760 nm wavelength. Such LEDs are usually made of gallium arsenide or alumunium gallium arsenide.

They, along with IR receivers, are commonly used as sensors.

The appearance is same as a common LED. Since the human eye cannot see the infrared radiations, it is not

possible for a person to identify whether the IR LED is working or not. To overcome this problem, the

camera on a cell phone can be used. The camera can show us the IR rays being emanated from the IR LED

in a circuit.

Fig :41

46

fig :42

PHOTO TRANSISTOR :

A photodiode is a type of photo detector capable of converting light into either current or voltage,

depending upon the mode of operation.

Photodiodes are similar to regular semiconductor diodes except that they may be either exposed or

packaged with a windows or optical fibre connection to allow light to reach the sensitive part of the

device.

Many diodes designed for use specifically as a photodiode will also use a PIN junction rather than

the typical PN junction.

The photo transistor is used for the amplification.

Fig :43

47

VARIABLE RESISTOR :

An electronic component that is used to vary the amount of current that flows through a circuit. It

works by sliding a wiper terminal across a resistive material, typically a thin film or chunk of carbon

or a resistive wire made of nickel chromium or tungsten alloys.

Potentiometers and rheostats are variable resistors in which the wiper terminals take the form of a

dial or slider that the user does manipulate, such as the volume control of radio or music system.

The variable resistor is measures distance to detect the object.

Fig :44

As the wiper is moved across the body of the device, the resistance increases between the wiper terminal and

one end terminal and decreases between the wiper and the other end.

Fig :45

555TIMER

The 555 timer is flexible, cheap, and easy to find.

48

It's also a great starting point for audio projects because its output can be wired directly to a speaker.

The 8-pin 555 timer must be one of the most useful ICs ever made and it is used in many projects.

With just a few external components it can be used to build many circuits.

The 555 timer is used to create pulse.

Fig :46

A popular version is the NE555 and this is suitable in most cases where a '555 timer' is specified. The 556 is

a dual version of the 555 housed in a 14-pin package, the two timers share the same power supply pins. The

circuit diagrams on this page show a 555, but they could all be adapted to use one half of a 556.

RESISTOR

• A resistor is a component of an circuit that resists the flow of electrical current.

• It has two terminals across which electricity must pass, and it is designed to drop the voltage

of the current as it flows from one terminal to the other.

• Resistors are primarily used to create and maintain known safe currents within electrical

components.

Resistance is measured in ohms, after Ohm' law. This law states that electrical resistance is equal to the

drop in voltage across the terminals of the resistor divided by the current being applied. A high ohm rating

indicates a high resistance to current. This rating can be written in a number of different ways — for

example, 81R represents 81 ohms, while 81K represents 81,000 ohms.

The amount of resistance offered by a resistor is determined by its physical construction. A carbon

composition resistor has resistive carbon packed into a ceramic cylinder, while a carbon filmresistor consists

of a similar ceramic tube, but has conductive carbon film wrapped around the outside. Metal film or metal

49

oxide resistors are made much the same way, but with metal instead of carbon. A wirewound resistor, made

with metal wire wrapped around clay, plastic, or fiberglass tubing, offers resistance at higher power levels.

Those used for applications that must withstand high temperatures are typically made of materials such as

cermet, a ceramic-metal composite, ortantalum, a rare metal, so that they can endure the heat.

Fig : fig :48

CAPACITOR

• A capacitor is a passive electronic component that stores f in form of an electrostatic field.

• In its simplest form, a capacitor consists of a conducting plates separated by an insulating material

called the dielectric.

• The capacitance is directly proportional to the surface areas of the plates, and is inversely

proportional to the separation between the plates. Capacitance also depends on the dielectric constant

of the substance separating the plates.

Fig :49

50

DC MOTOR

A DC motor is an electric motor that runs on direct current (DC) electricity. DC motors were used to

run machinery, often eliminating the need for a local steam engine or internal combustion engine.

DC motors can operate directly from rechargeable batteries, providing the motive power for the first

electric vehicles. Today DC motors are still found in applications as small as toys and disk drives, or

in large sizes to operate steel rolling mills and paper machines. Modern DC motors are nearly always

operated in conjunction with power electronic devices.

Lets start with how actually DC motor runs. Direction control of a DC motor is very simple, just

reverse the polarity, means every DC motor has two terminals out. When we apply DC voltage with

proper current to a motor, it rotates in a particular direction but when we reverse the connection of

voltage between two terminals, motor rotates in another direction

Fig :50

The DC motor has two basic parts: the rotating part that is called the armature, and the stationary part

that includes coils of wire called the field coils. The stationary part is also called the stator.

The armature is made of coils of wire wrapped around the core, and the core has an extended shaft

that rotates on bearings.

The termination points are called the commutator , and this is where the brushes make electrical

contact to bring electrical current from the stationary part to the rotating part of the machine.

51

Fig :51

GSM(GLOBAL SYSTEM FOR MOBILE COMMUNICATION)

Fig :52

GSM TECHNOLOGY:

GSM, which stands for Global System for Mobile communications, reigns as the world’s most widely used

cell phone technology. Cell phones use a cell phone service carrier’s GSM network by searching for cell

phone towers in the nearby area.

The origins of GSM can be traced back to 1982 when the Grouped Special Mobile (GSM) was created by

the European Conference of Postal and Telecommunications Administrations (CEPT) for the purpose of

designing a pan-European mobile technology.

52

GSM supports voice calls and data transfer speeds of up to 9.6 Kbit/s, together with the transmission

of SMS (Short Message Service).

GSM operates in the 900MHz and 1.8GHz bands in Europe and the 1.9GHz and 850MHz bands in

the US. The 850MHz band is also used for GSM and 3G in Australia, Canada and many South

American countries. By having harmonized spectrum across most of the globe, GSM’s international

roaming capability

It allows users to access the same services when travelling abroad as at home. This gives consumers

seamless and same number connectivity in more than 218 countries.

GSM is a globally accepted standard for digital cellular communications.

GSM uses narrowband Time Division Multiple Access (TDMA) for voice and Short Messaging

Service (SMS).

What is GSM?

If you are in Europe, Asia or Japan and using a mobile phone then most probably you must be using GSM

technology in your mobile phone.

GSM stands for Global System for Mobile Communication and is an open, digital cellular

technology used for transmitting mobile voice and data services.

The GSM emerged from the idea of cell-based mobile radio systems at Bell Laboratories in the early

1970s.

The GSM is the name of a standardization group established in 1982 to create a common European

mobile telephone standard.

The GSM standard is the most widely accepted standard and is implemented globally.

The GSM is a circuit-switched system that divides each 200kHz channel into eight 25kHz time-slots.

GSM operates in the 900MHz and 1.8GHz bands in Europe and the 1.9GHz and 850MHz bands in

the US.

The GSM is owning a market share of more than 70 percent of the world's digital cellular

subscribers.

The GSM makes use of narrowband Time Division Multiple Access (TDMA) technique for

transmitting signals.

The GSM was developed using digital technology. It has an ability to carry 64 kbps to 120 Mbps of

data rates.

53

http://www.tutorialspoint.com/gsm/tdma_and_cdma.htm

Presently GSM support more than one billion mobile subscribers in more than 210 countries

throughout of the world.

The GSM provides basic to advanced voice and data services including Roaming service. Roaming

is the ability to use your GSM phone number in another GSM network.

A GSM digitizes and compresses data, then sends it down through a channel with two other streams of user

data, each in its own time slot. It operates at either the 900 MHz or 1,800 MHz frequency band.

Why GSM?

The GSM study group aimed to provide the followings through the GSM:

Improved spectrum efficiency.

International roaming.

Low-cost mobile sets and base stations (BSs)

High-quality speech

Compatibility with Integrated Services Digital Network (ISDN) and other telephone company

services.

Support for new services.

Gsm specification

Specifications for different Personal Communication Services (PCS) systems vary among the

different PCS networks. The GSM specification is listed below with important characteristics.

Modulation:

Modulation is a form of change process where we change the input information into a suitable format

for the transmission medium. We also changed the information by demodulating the signal at the

receiving end.

The GSM uses Gaussian Minimum Shift Keying (GMSK) modulation method.

Access Methods:

Because radio spectrum is a limited resource shared by all users, a method must be devised to divide

up the bandwidth among as many users as possible.

GSM chose a combination of TDMA/FDMA as its method. The FDMA part involves the division by

frequency of the total 25 MHz bandwidth into 124 carrier frequencies of 200 kHz bandwidth.

54

One or more carrier frequencies are then assigned to each BS. Each of these carrier frequencies is

then divided in time, using a TDMA scheme, into eight time slots. One time slot is used for

transmission by the mobile and one for reception. They are separated in time so that the mobile unit

does not receive and transmit at the same time.

Transmission Rate:

The total symbol rate for GSM at 1 bit per symbol in GMSK produces 270.833 K symbols/second.

The gross transmission rate of the time slot is 22.8 Kbps.

GSM is a digital system with an over-the-air bit rate of 270 kbps.

Frequency Band:

The uplink frequency range specified for GSM is 933 - 960 MHz (basic 900 MHz band only).

The downlink frequency band 890 - 915 MHz (basic 900 MHz band only).

Channel Spacing:

This indicates separation between adjacent carrier frequencies. In GSM, this is 200 kHz.

Speech Coding:

Speech is encoded at 13 kbps.

Gsm is a TDMA based wireless network technology developed in Europe that is used throughout

most of the world. GSM phones make use of a SIM card to identify the user's account. The use of the

SIM card allows GSM network users to quickly move their phone number from one GSM phone to

another by simply moving the SIM card. Currently GSM networks operate on the 850MHz,

900MHz, 1800MHz, and 1900MHz frequency bands. Devices that support all four bands are called

quad-band, with those that support 3 or 2 bands called tri-band and dual-band, respectively. In the

United States, Cingular operates on the 850 and 1900MHz bands, while T-Mobile operates only on

the 1900MHz band.

Also known as: "Global System for Mobile Communications", "Groupe Special Mobile"

TDMA stands for time division multiple access. TDMA is a multiplexing method that divides

network connections into time slices, where each device on the TDMA network connection gets one

or more time slices during which it can transmit or receive data. TDMA is often used to refer to

early digital mobilephone networks that made use of TDMA multiplexing, such as the original

55

http://www.mobileburn.com/definition.jsp?term=TDMA

http://www.mobileburn.com/definition.jsp?term=GSM

http://www.mobileburn.com/definition.jsp?term=GSM

network implemented by AT&T/Cingular before it moved to GSM, which is itself based on TDMA

technology.

Also known as: "Time Division Multiple Access

RS 232 CONVERTER (MAX 232N) :

UART (Universal Asynchronous Receiver Transmitter) or USART (Universal Synchronous

Asynchronous Receiver Transmitter) are one of the basic interface which you will find in almost all

the controllers available in the market till date. This interface provide a cost effective simple and

reliable communication between one controller to another controller or between a controller and PC.

RS 232 BASIC:

RS-232 (Recommended Standard 232) is a standard for serial binary data signals connecting between

a DTE (Data terminal equipment) and a DCE (Data Circuit-terminating Equipment).

Voltage Levels:

The RS-232 standard defines the voltage levels that correspond to logical one and logical zero levels.

Valid signals are plus or minus 3 to 25 volts. The range near zero volts is not a valid RS-232 level;

logic one is defined as a negative voltage, the signal condition is called marking, and has the

functional significance of OFF. Logic zero is positive, the signal condition is spacing, and has the

function ON.

So a Logic Zero represented as +3V to +25V and Logic One represented as -3V to -25V.

Usually all the digial ICs works on TTL or CMOS voltage levels which cannot be used to

communicate over RS-232 protocol. So a voltage or level converter is needed which can convert

TTL to RS232 and RS232 to TTL voltage levels.

The most commonly used RS-232 level converter is MAX232. This IC includes charge pump which

can generate RS232voltage levels (-10V and +10V) from 5V power supply. It also includes two

receiver and two transmitters and is capable of full-duplex UART/USART communication.

This is the device, which is used to convert TTL/RS232 vice versa. RS-232 pin-outs for IBM

compatible computers are shown below. There are two configurations that are typically used: one

for a 9-pin connector and the other for a 25-pin connector.

56

http://www.mobileburn.com/definition.jsp?term=TDMA

Table-10

SERIAL COMMUNICATION:

The MAX232 is a dual driver/receiver that includes a capacitive voltage generator to supply EIA-232

voltage levels from a single 5-V supply. Each receiver converts EIA-232 inputs to 5-V TTL/CMOS

levels. These receivers have a typical threshold of 1.3 V and a typical hysteresis of 0.5 V, and can

accept 30-V inputs. Each driver converts TTL/CMOS input levels into EIA-232 levels. The driver,

receiver, and voltage-generator functions are available as cells in the Texas Instruments

LinASIClibrary.

Fig:53

Diagram above shows the waveform in which the bits has to be transferred. First is the start bit.. then

8-bit data and at last a stop bit. There is a secret formula to calculate the delay time which is needed

between bits to get correct baudrate. Below is a software implemented UART, which can be used in

C as well as Assembly programs. It is written for Keil software. But with a little modification you

can use it in your programs.57

CIRCUIT DIAGRAM

Fig :54

58

Fig : 55

SIM 300:

It is a GSM modem. And the interface techniques are RS232. It used for wireless Message communication

1:Tri-band (900/1800/1900) GPRS Class 10

2: 40x33x2.85mm 60-pin ENTERY bord to bord connecter

3: Sleep mode (about 2.5mA)

4: Embedded TCP/IP with transparent mode

5: Autobauding

6: Over-temperature automatic shutdown

7: SIM card detection function

8: All software version based on V10.0

59

CONNECTION OF SIM 300 & 8051

Fig : 56

60

Designed for global market, SIM300 is a Tri-band GSM/GPRS engine that works on frequencies EGSM 900

MHz, DCS 1800 MHz and PCS1900 MHz. SIM300 provides

GPRS multi-slot class 10 capability and support the GPRS coding schemes CS-1, CS-2, CS-3

The physical interface between SIM300 and the mobile application is through a 60 pins board-to-

board connector, which provides all hardware interfaces from module to customers’ boards except

the RF antenna interface.

The keypad and SPI LCD interface will give you the flexibility to develop customized applications.

Two serial ports can help you easily develop your applications.

Two audio channels include two microphones inputs and two speaker outputs. These audio interfaces

can be easily configured by AT command.

One ADC input SIM card

Following is the reference circuit about SIM interface. We recommend an Electro-Static discharge

device ST (www.st.com) ESDA6V1W5 or ON SEMI (www.onsemi.com) SMF05C for “ESD

ANTI”. The resistors (R204-R206) showed in the figure 3 should be added in series on the IO line

between the module and the SIM card for matching the impedance The SIM_PRESENCE pin is used

for detecting the SIM card removal. Note: The pull up resistor R207 must be added.

You can select the 8 pins SIM card. The reference circuit about SIM card illustrates as following

figure.

61

AT COMMAND

Table-11

62

Command Description

AT+CMGD DELETE SMS MESSAGE

AT+CMGF SELECT SMS MESSAGE

FORMAT

AT+CMGL LIST SMS MESSAGES FROM

PREFERRED STORE

AT+CMGR READ SMS MESSAGE

AT+CMGS SEND SMS MESSAGE

AT+CMGW WRITE SMS MESSAGE TO

MEMORY

AT+CMSS SEND SMS MESSAGE FROM

STORAGE

AT+CMGC SEND SMS COMMAND

AT+CNMI NEW SMS MESSAGE

INDICATIONS

AT+CPMS PREFERRED SMS MESSAGE

STORAGE

AT+CRES RESTORE SMS SETTINGS

AT+CSAS SAVE SMS SETTINGS

AT+CSCA SMS SERVICE CENTER

ADDRESS

AT+CSCB SELECT CELL BROADCAST

SMS MESSAGES

AT+CSDH SHOW SMS TEXT MODE

PARAMETERS

AT+CSMP SET SMS TEXT MODE

PARAMETERS

AT+CSMS SELECT MESSAGE SERVICE

PROGRAMME

Sensor port equ p1KEYS EQU P1RELAY EQU P0.3rs equ p0.1en equ p0.0rw equ p0.2lcdport equ p2PRDT EQU P3.6 ;PRODUCT SENSORPRDTSTPSW EQU P3.4;PRODUCT COUNT STOP SWITCHWRKRSTP EQU P3.5;WORKER COUNT STOP

;=====================================worker init.

EN1 EQU P0.4;DC MOTOR ENABLE PINL1 EQU P0.5;DC MOTOR 1ST PINL2 EQU P0.6;DC MOTOR 2ND PINORG 00HLJMP MAIN

SJMP PRODUCTORG 30H;{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{PRODUCT START{{{{{{{{{{{{{{{{{{{{{PRODUCT:SETB IE.7SETB IE.0

ACALL COMMAND2 mov dptr, #PRODUCT1 ;FOR PRROECT NAME........

acall dataaACALL COMMAND2MOV R7,#30HMOV A,R7ACALL DATAWRI:JB PRDT,XXX1 SJMP XXXXXX1:JB PRDTSTPSW,ISJMP PFINISH

63

XXX:INC R7ACALL CO1SJMP ICO1:

CJNE R7, #31H , NXT20 ;MOV A, R7 ACALL ADDR ACALL DATAWR; ACALL DCSTART ;SETB RLY1 ;SETB RLY2 RETNXT20: CJNE R7, #32H , NXT30 ;MOV A, R7 ACALL ADDR ACALL DATAWR RETNXT30: CJNE R7, #33H , NXT40 MOV A, R7 ACALL ADDR ACALL DATAWR RETNXT40: CJNE R7, #34H , NXT50 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT50: CJNE R7, #35H , NXT60 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT60: CJNE R7, #36H , NXT70 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT70: CJNE R7, #37H , NXT80 MOV A, R7

64

ACALL ADDR ACALL DATAWR RET NXT80: CJNE R7, #38H , NXT90 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT90: CJNE R7, #39H , NXT0A0 MOV A, R7 ACALL ADDR ACALL DATAWR

ACALL sendsms;...................EDIT........... mov dptr,#message7 ;.................

call senddata ;....................

RET NXT0A0: CJNE R7, #3AH , co1 MOV R7, #30H MOV A, #30H ACALL ADDR ACALL DATAWR

RET

PFINISH: acall command2

mov dptr, #PRODUCT2 ;FOR PRROECT NAME........acall dataa ACALL sendsms mov dptr,#message7 ;.................

call senddata mov scon,#50h

mov tmod,#20h mov th1,#0fdh

reti

;{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{;*********************************************PASSWORD

START**********************************************MAIN:

65

clr relaySETB IE.7SETB IE.0SETB IE.2

MOV KEYS, #0FFHMOV R1, #01H

ACALL COMMAND2MOV 30H, #11111110B ;1........INITIAL P.W=123MOV 31H, #11111101B ; 2........MOV 32H, #11111011B ; 3........

NEW2:MOV KEYS, #0FFHACALL MMOV 33H, A ;1ST CHAR IN 33HACALL DISPLAY1MOV KEYS, #0FFHACALL MMOV 34H, AACALL DISPLAY2MOV KEYS, #0FFHACALL M

MOV 35H, AACALL DISPLAY3ACALL COMP

NEW4:CJNE R1, #03H, NEW ;...........COUNTER SET 3 ...........LJMP NEW3

COMP:MOV A, 30H;MOV R2, 33HCJNE A, 33H, NEW4MOV A, 31HCJNE A, 34H, NEW4MOV A, 32HCJNE A, 35H, NEW4ACALL CORRECT

NEW3:ACALL WRONG;CPL RELAY;ACALL DELAY;CPL RELAYSJMP MAIN

;==========================================================DISPLAY=======================================

66

CORRECT: ACALL COMMAND2

B_1:mov dptr, #mydata1 ;FOR PRROECT NAME........

BB_1:clr amovc a, @a+dptrjz CORRECTMSG ;jump a=0,acall datawr

;acall send inc dptr

sjmp BB_1CORRECTMSG:

ACALL SENDSMS ;TMT MSG INITIAISATION......mov dptr,#message4 ;MSG FOR CORRECT PASSWORD.....

call senddataSJMP $ ;###########################################jUMP TO WORKER

COUNT

;==========================================================================================================WRONG:;========================================================================================================== setb relay

ACALL COMMAND2mov dptr, #mydata2 ;FOR PRROECT NAME........

BB_10:clr amovc a, @a+dptrjz R ;jump a=0,acall datawr


sjmp BB_10R:WRONGMSG:

ACALL SENDSMS ;TMT MSG INITIAISATION......mov dptr,#message5 ;MSG FOR CORRECT PASSWORD.....

call senddata;SJMP $ ;***********STOP.........RET

;============================================================================================================

67

DISPLAY1:MOV A, #80HACALL COMMANDMOV A,#"*"ACALL DATAWR

ACALL DELAY0XRET

DISPLAY2:MOV A, #81HACALL COMMANDMOV A,#"*"ACALL DATAWR

ACALL DELAY0X RET

DISPLAY3:MOV A, #82HACALL COMMANDMOV A,#"*"ACALL DATAWRACALL DELAY0X

RETNEW:

ACALL COMMAND2INC R1LJMP NEW2

M:MOV A, KEYSCJNE A, #0FFH, RE ;CHK IF KEY IS

PRESSED OR NOTSJMP M

RE:

RET

;**********************************PASSW0RD END********************************** ;}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}

WORKER: WCOUNT: acall command2

mov dptr, #WORKER1 ;FOR PRROECT NAME........acall dataa

68

;==========================================================================================

sjmp main2

MAIN2:acall command2

SETB IE.7SETB IE.2

MOV R0,#30hMOV R7,#30hMOV P1,#0FFH;===================================================================MAIN PRO.===========

main3: JB WRKRSTP,AXLJMP WORKERFINISHAX:

mov a, sensorport cjne a, #10111111B, nxt sjmp enter

nxt: cjne a, #01111111b, main3 sjmp exit ;*********************************************************************enter: MOV A, sensorport CJNE A, #01111111B, enter INC R7 ACALL COMP1 MOV sensorport, #0FFH

ACALL DELAY0X LJMP MAIN3 ;=============================================================COMP1: CJNE R7, #31H , NXT2 ;MOV A, R7 ACALL ADDR ACALL DATAWR; ACALL DCSTART; SETB RLY1; SETB RLY2 RET

69

NXT2: CJNE R7, #32H , NXT3 ;MOV A, R7 ACALL ADDR ACALL DATAWR RETNXT3: CJNE R7, #33H , NXT4 MOV A, R7 ACALL ADDR ACALL DATAWR RETNXT4: CJNE R7, #34H , NXT5 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT5: CJNE R7, #35H , NXT6 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT6: CJNE R7, #36H , NXT7 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT7: CJNE R7, #37H , NXT8 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT8: CJNE R7, #38H , NXT9 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT9: CJNE R7, #39H , NXT0 MOV A, R7 ACALL ADDR ACALL DATAWR

70

RET NXT0: CJNE R7, #3AH , comp1 MOV R7, #30H MOV A, #30H ACALL ADDR ACALL DATAWR

RET ;================================================ ;*****************************************************EXIT: MOV A, sensorport CJNE A, #10111111B, EXIT DEC R7 MOV sensorport, #0FFH ACALL DELAY0X ACALL COMP2 LJMP MAIN3 CJNE R7, #2AH , COMP2 SJMP NNCOMP2: CJNE R7, #30H , NXT00 NN: MOV A, R7 ACALL ADDR ACALL DATAWR ;CLR RLY1 ;CLR RLY2 ;ACALL DCSTOP; SJMP MAIN2 RET NXT00: CJNE R7, #31H , NXT21 MOV A, R7 ACALL ADDR ACALL DATAWR RETNXT21: CJNE R7, #32H , NXT31 MOV A, R7 ACALL ADDR ACALL DATAWR RETNXT31: CJNE R7, #33H , NXT41

71

MOV A, R7 ACALL ADDR ACALL DATAWR RETNXT41: CJNE R7, #34H , NXT51 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT51: CJNE R7, #35H , NXT61 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT61: CJNE R7, #36H , NXT71 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT71: CJNE R7, #37H , NXT81 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT81: CJNE R7, #38H , NXT91 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT91: CJNE R7, #39H , NXT01 MOV A, R7 ACALL ADDR ACALL DATAWR RET NXT01: ;CJNE R7, #3AH , comp2 MOV R7, #30H MOV A, #30H ACALL ADDR ACALL DATAWR

72

LJMP MAIN3 WORKERFINISH: acall command2

mov dptr, #WORKER2 ;FOR PRROECT NAME........acall dataa ACALL sendsms;...................EDIT........... mov dptr,#message6 ;.................

call senddata mov scon,#50h

mov tmod,#20h mov th1,#0fdh

reti ;{{{{{{{{{{{{{{{{cOMMON START{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{ ;==============================================ADDR: MOV A, #80H ACALL COMMAND MOV A,R7 RET

;****************************************************GSM*********************************GSMTMT:;org 0000h ;clr p1.0; call sendsms ; setb p1.0;loop : jmp loop;=====================================================sendsms: mov dptr,#message1 call senddata call delay

mov dptr,#message3 call senddata call delay

ret;=====================================================message1: db "AT+CMGF=1", 0Dh, '$'message2: db "AT+CSCS=", '"', "GSM", '"', 0Dh, '$'

73

message3: db "AT+CMGS=", '"', "+918260324996", '"', 0Dh, '$'message4: db "CORRECT PASSWORD.", 0Dh, 1Ah, '$'message5: db "WRONG PASSWORD. ", 0Dh, 1Ah, '$'message6: db " WORKERS =9" ,'$'message7: db " PRODUCTS =9", '$';=====================================================senddata : mov scon,#50h mov tmod,#20h mov th1,#0fdh mov tl1,#0fdh mov 39h,#00h setb tr1

senddata2: mov a,39h movc a,@a+dptr

cjne a,#'$',senddata3 mov tmod,#11h ret

senddata3 : mov sbuf,a jnb ti,$ clr ti inc 39h jmp senddata2 delay:

MOV R2, #30HERE3: mov r3, #200here2: mov r4, #250here: djnz r4, here

djnz r3, here2DJNZ R2, HERE3

ret

;*******************************************************************************************

;===========================GSM TMT END=====================================================dataa :

74

mov 39h,#00hBx: clr a mov a,39h

movc a,@a+dptr

jz b_x2 ;jump a=0, acall datawr ;acall send inc 39h sjmp Bx

b_x2:retcommand:

mov lcdport,aclr rsclr rwsetb enacall delay0Xclr enret

datawr:mov lcdport,asetb rsclr rwsetb enacall delay0Xclr enret

delay0X:mov r4,#255

h2:mov r5,#255

h: djnz r5,hdjnz r4,h2ret

;==========================commcommand2:

mov dptr, #mycomh_1:;.............................

clr a75

movc a, @a+dptracall commandacall delay0Xjz xx ;jump a=0,


sjmp h_1xx:

ret

;==============================================================================================

mycom: db 38h,0eh,01,06,80h,0

mydata1:db "CORRECT PASSWORD",0mydata2:db " WRONG PASSWORD ",0PRODUCT1:db " PRODUCT COUNT ",0PRODUCT2:db "COUNTING END ",0WORKER1:db " WORKER COUNT. . ",0WORKER2:db "COUNTING END ",0mydata12:db "ENTER PASSWORD ",0END

;}}}}}}}}}}}}}}}}}}COMMON END}}}}}}}}}}}}}}}}}}}}}}

FUTURE SCOPE

The microcontroller can be used for implementation of more of more complex tasks like controlling

different systems in the industry. The project we have undertaken can be used as a reference or as a base for

realizing a scheme to be implemented in other projects of greater level. The project itself can be modified to

achieve a complete automation system which will then create a platform for the user to interface between

himself and his industry.

RECOMMENDATION

76

This project is a small implication of our concept in automating and monitoring system. The practical

applications of this project are immense and can have vast level of implementation. This small concept can

be used in fields such as weather forecasting, remote sensing, robotics, aeronautics, home automation, and

many other related fields where continuous monitoring and regulation is needed. So this is not the end of the

project but rather is a step towards exploring other possibilities that it brings with it. We recommend this

project, which has tremendous applications and possibilities. The project work in the fact gives a lot of

confidence to fight out in this challenging world.

APPLICATION

Industrial Automation

Visitor counting

Security access system

Home Automation

CONCLUSION

77

The project we have undertaken has helped us gain a better perspective on various aspects related to our

course of study as well as practical knowledge of electronic equipments and communication. We became

familiar with software analysis, designing, implementation, testing and maintenance concerned with our

project.

In this critical sensor monitoring, authentication is commanding the system and wireless network are

challenges faced by the industries. As the user operates the system by a secret code the authorization

problem has been solved.

The GSM network used helps in controlling the system from a distant area. The microcontroller used helps

in interfacing many input/output devices at a time.

These extensive capabilities of the system are what make it so interesting. From the convenience of a simple

cell phone, a user is able to control and monitor virtually any electrical devices.

The end product will have a simplistic design making it easy for the users to interact with.

BIBLIOGRAPHY

www.intel.com

78

http://www.intel.com/

www.atmel.com

www.maixm-ic.com

www.8052.com

www.keil.com

www.arm.com

www.simcom.com

www.engineergarage.com

Architecture and programming of micro controller 8051 –A.J.Ayala.

The 8051 microcontroller and Embedded systems –Mazidi and Mazidi

Intel micro book.

79

http://www.simcom.com/

http://www.arm.com/

http://www.keil.com/

http://www.8052.com/

http://www.maixm-ic.com/

http://www.atmel.com/

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Documents

GSM based manufacturing industrial automation