DIGITAL TACHOMETER AND REVOLUTION COUNTER FOR CAR

ENGINE

MUHAMMAD FARID BIN SAMSURY

This report is submitted in partial fulfillment of the requirements for the award of

Bachelor of Electronic Engineering (Computer Engineering) With Honours

Faculty of Electronic and Computer Engineering

Universiti Teknikal Malaysia Melaka

April 2009

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UNIVERSTI TEKNIKAL MALAYSIA MELAKA

FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER

BORANG PENGESAHAN STATUS LAPORAN

PROJEK SARJANA MUDA II

Tajuk Projek

: DIGITAL TACHOMETER AND REVOLUTION COUNTER FOR CAR ENGINE

Sesi Pengajian

: 2008/2009

Saya MUHAMMAD FARID BIN SAMSURY

(HURUF BESAR)

mengaku membenarkan Laporan Projek Sarjana Muda ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:

1. Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi

pengajian tinggi. 4. Sila tandakan ( √ ) :

SULIT*

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)

TERHAD*

(Mengandungi maklumat terhad yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

TIDAK TERHAD

Disahkan oleh:

__________________________ ___________________________________

(TANDATANGAN PENULIS) (COP DAN TANDATANGAN PENYELIA)

Alamat Tetap: Lot 583, Jalan Semabok Dalam,

Semabok, 75050,

Melaka.

Tarikh :…………………………………………………. Tarikh : ……………………………………………………………..

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“I hereby declare that this report is the result of my own work except for quotes as cited

in the references.”

Signature : ………………………………………

Author : MUHAMMAD FARID BIN SAMSURY

Date : …………………………………………..

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“I hereby declare that I have read this report and in my opinion this report is sufficient in

terms of the scope and quality for the award of Bachelor of Electronic Engineering

(Computer Engineering) With Honours.”

Signature : …………………………………………..

Supervisor’s Name :

Date : ………………………………………….

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Specially dedicated to my beloved family especially my parents and family members.

Last but not least, to my supervisor, my friends and all the UTeM lecturers.

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ACKNOWLEDGEMENT

First and foremost I would like to extend my heartfelt gratitude to all that have

been contributed especially to my supervisor Professor Madya Dr. Ahmad Jamal Bin

Salim for his supervision and guidance. Then, I want to express my special thank to all

the FKEKK staff, PSM committee for their time, patience and professionalism. Beside

that, my appreciation goes to my beloved parents and to all my extended family because

of their full support, inspiration and encouragement in doing this project. Without their

support, this project may have not come to fruition. There are other thank, namely those

with whom I did not pleasure of interacting personally, but whose contributions are

extremely valuable, nevertheless.

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ABSTRACT

Nowadays, the usage of digital tachometer is rare and revolution counter is non

existent due to the fact that these electronic devices are quite expensive in the market. A

digital tachometer and revolution counter will be displaying digitally the revolution per

minute and total number of engine revolution of a car’s engine on the liquid crystal

display. The digitally displays are more accurate and precise compared to analogue. A

tachometer is a device that measures the rotation speed of a shaft in a car’s engine. A

revolution counter concept is similar to an odometer where the revolution counter

measures the rotation of crankshaft coverage while the odometer measures the distance

coverage. The main objective of this project is to design and develop a low cost digital

tachometer and revolution counter by using Microchip PIC microcontroller. A car

maintenance schedule base on the total number of engine revolution will be proposed in

this project as a reference for the driver to do his car maintenance. There are four phases

of methodology to complete this project which are literature review, PIC source code

development, hardware development and thesis writing. The expected result of this

project is that, the circuit will be able to measure and display the revolution per minute

readings and total number of engine revolution digitally on the liquid crystal display.

Hopefully, this project can be implemented in our national automotive industry.

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ABSTRAK

Pada masa kini, penggunaan takometer digit amat terbatas dan pembilang

putaran masih belum direka disebabkan faktor harga perkakasan elektronik terbabit amat

mahal di dalam pasaran. Secara asasnya, takometer dan pembilang putaran memaparkan

bacaan putaran per minit dan jumlah putaran engkol enjin kereta secara digit di paparan

hablur cecair. Projek ini memberikan bacaan digit yang tepat berbanding dengan bacaan

analog. Konsep mengira putaran adalah sama seperti odometer di mana pengiraan

putaran adalah mengukur putaran engkol manakala odometer pula adalah mengukur

jarak perjalanan kereta. Objektif utama projek ini ialah mereka bentuk dan

membangunkan takometer dan pembilang putaran digit yang murah dengan

menggunakan PIC. Satu jadual penyelenggaraan kereta berdasarkan jumlah putaran

engkol turut dicadangkan sebagai rujukan yang tepat untuk pemandu-pemandu kereta

melakukan penyelenggaraan dan pemeriksaan kereta. Metodologi projek ini dibahagikan

kepada empat fasa yang berlainan iaitu kajian latar belakang, membangunkan program

untuk PIC, membangunkan litar dan penulisan tesis. Jangkaan hasil untuk projek ini

ialah litar takometer dan pembilang putaran digit dapat mengukur putaran engkol dan

seterusnya memaparkan bacaaan putaran per minit and jumlah putaran engkol di paparan

hablur cecair. Secara amnya diharapkan, projek ini dapat digunakan di dalam industri

automotif Malaysia.

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TABLE OF CONTENT

CHAPTER TITLE PAGE

TITLE i

DECLARATION ii

DEDICATION v

ACKNOWLEDGEMENT vi

ABSTRACT vii

ABSTRAK viii

TABLE OF CONTENTS ix

LIST OF TABLES xiii

LIST OF FIGURES xiv

LIST OF ABBREVIATION xvi

LIST OF APPENDIX xvii

x

I INTRODUCTION 1

1.1 Introduction 1

1.2 Project Objectives 2

1.3 Problems Statement 2

1.4 Scope of Work 3

1.5 Short Brief of Project Methodology 3

1.6 Report Structure 4

II LITERATURE REVIEW

2.1 Introduction 5

2.2 The Operation Of Digital Tachometer and

Revolution Counter 6

2.2.1 Electronic Control Unit 7

2.3 Crankshaft 9

2.3.1 The Basic Operation of Crankshaft 10

2.4 The Total Number of Engine Revolutions 15

2.5 Car Maintenance Schedule 17

2.5.1 Advantage of Car Maintenance Schedule

Based On the Total Number of Engine

Revolution 22

2.6 Microchip PIC Microcontroller 22

2.6.1 PIC Microcontroller 24

2.6.2 Limitations of PIC 25

2.6.3 Applications of PIC 26

2.7 Liquid Crystal Display 26

2.8 Light Emitting Diode 30

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2.9 Function Generator 31

III METHODOLOGY 32

3.1 Introduction 32

3.2 Flowchart of Project Methodology 33

3.2.1 The Explanation of the Flowchart 36

3.2.1.1 Phase 1-Literature Review 36

3.2.1.2 Phase 2-PIC Source Code

Development 36

3.2.1.3 Phase 3-Hardware Development 37

3.2.1.4 Phase 4-Write Thesis 38

3.3 Gant Chart 38

3.4 Block Diagram of Project 40

3.5 Software Utilization 44

3.5.1 MPLAB 44

3.5.2 Proteus 7.0 45

3.5.3 Ares 7 46

3.5.4 Picshell 47

IV RESULT AND ANALYSIS 48

4.1 Introduction 48

4.2 Hardware Analysis 49

4.2.1 Power Circuit Analysis 51

4.2.2 Controller Circuit Analysis 52

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4.2.3 LCD Circuit Analysis 53

4.2.4 Hardware Assemble on Breadboard 54

4.2.5 Hardware Assemble on PCB 55

4.2.6 Hardware Casing 56

4.3 Software Analysis 58

4.4 Discussions 59

V CONCLUSION AND RECOMMENDATION 60

5.1 Introduction 60

5.2 Conclusion 61

5.3 Recommendation for Future Work 61

REFERENCES 62

APPENDIX A 66

APPENDIX B 86

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LIST OF TABLES

NO TITLE PAGE

2.1 The Various Firing Order 7

2.2 Transmission Ratio Proton GEN 2 1.6 16

2.3 Pin Information for LMB16AFC Controller Chip 27

2.4 Instruction Code 30

4.1 Interface between LCD Screen and PIC16F84 54

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LIST OF FIGURES

NO TITLE PAGE

2.1 The Basic Operation of Ignition System 6

2.2 ECU 8

2.3 Crankshaft 9

2.4 Basic Parts for Four Stroke Engine 10

2.5 Intake Stroke 12

2.6 Compression Stroke 13

2.7 Combustion Stroke 14

2.8 Exhaust Stroke 14

2.9 The Crankshaft Movement 15

2.10 Car Maintenance Schedule Based on the Total

Number of Engine Revolution 21

2.11 Harvard Architecture Block Diagram 24

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2.12 Types of PIC Microcontroller 25

2.13 LCD 26

2.14 Register Selection 28

2.15 LED 30

2.16 Function Generator 30

3.1 Flowchart of Project Methodology 33

3.2 Gantt Chart 36

3.3 Block Diagram of Digital Tachometer and

Revolution Counter 37

3.4 Flowchart Calculations of RPM 39

4.1 The 3 Main Block Diagram 49

4.2 Simulation using Multisim Power Supply Circuit 50

4.3 Control Circuit Analysis 51

4.4 LCD Screen Circuit 52

4.5 Hardware Assemble Breadboard 54

4.6 Display RPM and REV 54

4.7 PCB Layout 55

4.8 PCB 55

4.9 Stripboard 56

4.10 Casing of DTRC 57

4.11 Front View 57

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LIST OF ABBREVIATION

RPM – Revolution per Minute

PIC – Peripheral Interface Controller

PSM – Projek Sarjana Muda

LCD – Liquid Crystal Display

PCB – Printed Circuit Board

IC – Integrated Circuit

LED – Light Emitting Diode

VSM - Virtual System Modelling

DTRC – Digital Tachometer and Revolution Counter

RPS – Revolution per Second

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LIST OF APPENDIX

NO TITLE PAGE

A Assembly Language Programming 65

B Electronic Circuit Schematic 86

1

CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

A tachometer is an instrument that measures the rotation speed of a shaft or disk,

as in a motor or other machine. The device usually displays the revolutions per minute

(RPM) on a calibrated analog dial, but digital displays are increasingly common. The

term comes from Greek Ταχος, tachos, "speed", and metron, "to measure"[1]. Basically,

the purpose of digital tachometer can assist the driver in selecting appropriate throttle

and gear settings for driving conditions. Thus, the prolonged use at high speeds may

cause excessive wear and the other damages to engine. A revolution counter is an

electronic instrument that measures the average of each of rotation shaft in car engine.

The device usually displays the total number of engine revolutions in revolution (Rev).

2

The purpose of digital revolution counter is more as a reference to the engine lifetime

and do car maintenance schedule. The car maintenance schedule such as changing the

spark plugs, timing belt, engine oil, gear oil, oil filter and the others was proposed based

on the total number of engine revolution recorded. These two instruments were

implemented and also combined together in one system using the Microchip PIC

microcontroller. The digital tachometer and revolution counter will give more accurate

reading compared to analogue reading. The usage of digital tachometer is rare because

the price is quit expensive while digital revolution counter is non existent. So, the

purpose of this project is to build a low cost and efficient digital tachometer and

revolution counter by using Microchip PIC Microcontroller.

1.2 PROJECT OBJECTIVES

The main objective of this project is to design and develop a low cost digital

tachometer and revolution counter using Microchip PIC Microcontroller. A maintenance

schedule will be proposed based on the total number of engine revolution.

1.3 PROBLEM STATEMENT

Nowadays, everybody wants good quality equipment but the cost must be low. In

the market, the use of digital tachometer is rare and revolution counter is non existent.

Car users usually refer to the odometer to do their car maintenance. Basically, the

odometer measures the distance coverage only. So, the true condition of the lubrication

oil, spark plugs, oil filter and the others do not often relate to distance coverage. This

situation can be compared to city and country driving which obviously requires the

former one to change much earlier in time the engine oil, spark plugs, oil filter and

others.

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1.4 SCOPE OF WORK

In this project, there are three scope of work that must be implemented to make

sure the project is successful. Firstly, design a low cost circuit by using Microchip PIC

microcontroller. Secondly, program the PIC for this project. Thirdly, propose a

maintenance schedule for car such as changing engine oil, oil filter, transmission oil,

spark plugs and the others.

1.5 SHORT BRIEF OF PROJECT METHODOLOGY

In this PSM I, project methodology is divided into literature review, PIC source

code development and hardware design development. The combination of both parts

will be added on the PSM II report. The project methodology details are shown in

Chapter 3 of this report.

In literature review, all the information regarding this project will be stated such

as the type of PIC to use, types of LCD, the operations of electronic tachometer, the

operations of crankshaft, the car maintenance schedule and the others.

In the PIC source code development, the PIC source code for this project will be

developed by using MPLAB software. The MPLAB software was used to build the

source code or program in assembly language.

In the hardware development, the circuit will be simulated in Proteus software.

Once the simulation is correct, the circuit will be tested on the breadboard. After that,

the circuit will be transferred on the PCB when all the connections on the breadboard are

running properly. The LCD is used to display values of RPM and total number of engine

revolutions.

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1.6 REPORT STRUCTURE

This report consists of five chapters which are Introduction, Literature Review,

Methodology, Result and Discussion, and Conclusion and Suggestion.

In Chapter 1 is introduction. It discussed about project background, project

objectives, problem statement, scope of work, short brief of project methodology and

overview of the remaining chapters.

In Chapter 2 is literature review. It reviews some references from previous

project, journals, articles, books and datasheet. All the materials are useful information

to this project.

In Chapter 3 is methodology. It discusses the approach to complete this project.

This project was divided into two parts which are software development and hardware

design. The details of the process for both parts will be presented in this chapter.

In Chapter 4 is result and discussion. It shows the result that had been obtained in

this project.

In Chapter 5 is conclusion and suggestion. It concludes the entire project and

proposes some future plan for this project.

5

CHAPTER 2

LITERATURE REVIEW

2.1 INTRODUCTION

A literature review is a body of text that aims to review the critical points of

current knowledge on a particular topic. This chapter reviews some references from

previous projects, journals, articles, books and datasheet. All these information was

collected from different sources such as library, internet and product manual. The useful

data of this project will be discussed in this chapter. This chapter will study the

fundamental theories on an electronic tachometer, the engine revolutions mechanism,

the car maintenance schedule, the Microchip PIC microcontroller and others.

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2.2 THE OPERATION OF DIGITAL TACHOMETER AND REVOLUTION COUNTER

The signal driving digital tachometer and revolution counter is originate from an

ignition coil. An ignition coil is an induction coil in an automobile’s ignition systems

which transform the battery 12V to the thousand of volts needed to ignite the spark plug

[2]. Firstly, the ignition system will produce a high voltage electrical charge and

transmits it to the spark plugs via ignition wires. The first electrical charge flows to the

distributor. The distributor is to distribute the high voltage from the coil to the cylinders

to perform the power stroke or combustion stroke. Thus, the distributor has one wire

going in the center and some wires on the number of cylinders such as 4, 6 or 8 wires

coming out of it. These ignition wires send the charge to each spark plug. The engine is

timed so that only one cylinder receives a spark from the distributor at a time. The

ignition system is shown in Figure 2.1.

Figure 2.1 The Basic Operation of Ignition System

7

The sequence spark plugs ignition is called the firing order. The firing order is

the order in which combustion is initiated in an internal combustion engine and normally

it starts from cylinder number 1. There are various firing orders for different engine

layouts as shown Table 2.1[4].

Table 2.1 The Various Firing Order

Number of Cylinder Firing Order

3 1-3-2

4 1-3-4-2

5 1-2-4-5-3

6 1-5-3-6-2-4

A four stroke engine requires four strokes of the piston which are two up and two

down movement. So, one complete combustion cycle of ignition system will make two

revolutions of crankshaft. That means one revolution of crankshaft needs 2 pulses of

ignitions [5].

2.2.1 ELECTRONIC CONTROL UNIT

In modern car, the digital tachometer and revolution counter get the input signal

which is ignition coil signal from the electronic control unit compare to the old car

where a tachometer get the signal from contact breaker. An electronic control unit is an

embedded system that controls one or more of the electronic systems or subsystems in a

vehicle [6]. Normally, an electronic control unit has many control unit such as