CHAPTER: - 1

INTRODUCTION

1

1.1 PROBLEM SUMMARY

REVOLUTION PER MINUTES (RPM) INDICATOR is a system in which we get the speed

of rotation of rotating machine. In past, we connect instrument with rotating parts. So that, To

improve accuracy of this instrument we are going to make it contactless. The RPM reading will

be sent to operator using GSM modem.

1.2 DETAILED DESCRIPTION OF PROBLEM

In Agriculture & Industry, When Power supply varies frequently, RPM also varies. From RPM,

we can know power supply status. Due to High and low power supply, We lost rotating

equipment like electrical motor. To resolve this problem, we will make this instrument.

The Infra-Red sensor is placed in front of shaft of motor. A silver slit is placed along the

diameter of shaft of motor.

The sensor transmits light on the shaft. Light is reflected when strikes with slit on shaft.

Reflected signal is converted in pulses which is gives to the microcontroller. Based on

computation done in microcontroller, we get the RPM of testing device. This detail is display on

LCD16x2 and send to the operator through GSM module.

From RPM , we can know status of power supply & if supply high or low then we cutoff supply

to rotating instrument automatically by Microcontroller.

2

CHAPTER: - 2

LITERATURE SURVEY

3

2.1 Introduction

Digital RPM indicator are particularly suitable for the precision measurement and

monitoring of all time related quantities, which are able to be converted into a proportional

frequency using the appropriate sensors. Time-related quantities include rotational and linear

velocity, flow rate and related quantities. The instrument can be programmed to measure

absolute values ratio, or proportional frequency.

The proportional frequency is generally produced by a magnetic wheel mounted on the

shaft, which is scanned by a radial mounted impulse sensor. For control applications, a high

resolution pick-up can be coupled directly to the motor shaft. The digital tachometer implements

the period measurement method, with the subsequent calculation of a reciprocal value. Two

absolute values, with independent set-up parameters, or their ratio or proportional difference

(selectable) can be measured. The measurement is carried out automatically and repetitively, or

externally through a contact. In ratio and proportional difference modes, the values used in the

calculation are acquired simultaneously. These values are taken at the same point in time,

without a delay, whereby a higher accuracy can be attained. In contemporary implementations,

the values are taken successively.

The first prototypes were based on optical sensors since these are normally easy to find.

The first prototype was a wire wrapped design using the 8052 based microcontroller driving 8 of

seven segment LED display characters. The sensor was an optical reflector sensor much like the

Fairchild semiconductor qrb1114. The advantage to these sensors types is that they are usually in

stock and very cheap. The sensor contains both an infra-red LED and infra-red photo NPN

transistor as a detector. Both the sensor and detector are contained in an angled plastic case with

a focal point approximately 2 inches from the sensor.

4

2.2 Infra- Red Sensor

FIG 2.1Internal circuit for Infra-Red sensor

One problem with these sensors is that they produce a very small signal depending on the

type of material used to reflect infra-red light from the led into the detector and the distance from

the material. An operational amplifier circuit can be used to amplify this signal to a more usable

level. The idea behind most digital counting tachometers is a micro-controller, used to count the

Pulses of a sensor or any other electronic device.

In the case of this tachometer, the counted pulses comes from infra-red sensor, which

detects any reflective element that passed in front of it, and thus, gives an output pulse for each

and every rotation of the shaft. Those pulses are fed to the microcontroller and counted. The

main difference of tachometer and frequency meters is that the reading in pulses per minutes (to

count revolutions per minutes) is needed but in the same time, one does not want to wait a whole

minute before obtaining a correct reading. Thus additional processing to predict the number of

revolutions per minute in less than a second. It's necessary to be able to deduce an RPM reading

5

in less than second, while constantly refining the reading's accuracy, a simple algorithm have

been developed, where a counter and a timer are used. Counter and timers are part of the internal

features of a micro-controller, (like the AT89C52 used for the first prototype) and they can be

easily configured through programming.

The counter is connected in such a way as to count pulses coming from the infra-red

sensor, while the timer is used to precisely feed the counted value to the microcontroller every

fifth of a second, and reset the counter to 0. The microcontroller can now take an average of the

last 3 readings (saved in C1, C2 and C3) and calculate the average numbers of pulses per fifth

second, later this value is multiplied by 5 to get the number of pulses per second. Later this value

is multiplied by 60 to get the number of pulses per minute, which represents the measured RPM.

FIG 2.2 pulse calculation for RPM measurementThe only purpose of calculating an average reading is that it allows more stable reading

to be obtained and prevent fluctuating of the display. The problem with this method is that one

cannot measure rpm values less that 60 rpm with a single pulse. Multiple pulses are required to

improve the tachometer's accuracy.

6

CHAPTER:- 3

TECHNICAL SPECIFICATIONS

7

3.1 SYSTEM SPECIFICATION

ELECTRICAL:

1. Power supply voltage : 5v DC

2. Supply current required : 2000mA maximum

ENVIRONMENTAL:

1. Temperature : 10°c to 60°c

2. Humidity : 40%

MECHANICAL:

1. Module size : 700×400×25 mm(Approx)

8

3.2 COMPONENT SPECIFICATION

Micro controller ATMEL89CS52

Operating voltage: 5.0V

Temperature range: -40Cc to 125Cc

Power Consumption: 12mA

IR Proximity Sensor

Supply Voltage 4.5 to 5.5VDC

Temperatures range: -40Cc to 85Cc

Sensing range 0 to 80cm

GSM module SIM900

Operating voltage 10 to 12v

Temperature range -30C to 80Cc

LCD 16x2 Display

Operating voltage 4.7 to 5.3 V

Temperature range -20Cc to 70Cc

Power Consumption 0.35mA

9

CHAPTER:- 4

HARDWARE DESCRIPTION

10

4.1 BLOCK DIAGRAM

`

FIG 4.1 Block diagram of Digital RPM measurement over GSM

11

MOTOR

(12V)

PROXIMITY

SENSOR

POWER

SUPPLY

MICROCONTROLLER

(5V)

OPERATOR

GSM

MODULE

LCD 16x2

4.2 COMPONENT LIST&DESCRIPTION:

Component List:

1. Microcontroller AT89C52

2. IR Proximity sensor

3. 16x2 LCD (JHD162A)

4. GSM Module (SIM900)

5. Resistors

6. Capacitors

7. 12V DC Motor (Testing Device)

8. Battery (9v) & Battery Connector

12

4.2.1 Microcontroller AT89C51

Features:

Compatible with MCS®-51 Products

8K Bytes of In-System Programmable (ISP) Flash Memory – Endurance: 10,000

Write/Erase Cycles

4.0V to 5.5V Operating Range

Fully Static Operation: 0 Hz to 33 MHz

Three-level Program Memory Lock

256 x 8-bit Internal RAM

32 Programmable I/O Lines

Three 16-bit Timer/Counters

Eight Interrupt Sources

Full Duplex UART Serial Channel

Low-power Idle and Power-down Modes

Interrupt Recovery from Power-down Mode

Watchdog Timer

Dual Data Pointer

Power-off Flag

Fast Programming Time

Flexible ISP Programming (Byte and Page Mode)

13

4.2.2 PIN DIAGRAM :

FIG 4.2 Pin configuration & Block diagram of 8051 microcontroller

The whole configuration is obviously thought of as to satisfy the needs of most

programmers working on development of automation devices. One of its advantages is that

nothing is missing and nothing is too much. In other words, it is created exactly in accordance to

the average user‘s taste and needs. Another advantage is RAM organization, the operation of

Central Processor Unit (CPU) and ports which completely use all recourses and enable further

upgrade.

PINOUT DESCRIPTION

(a) Pins 1-8 port 1 each of these pins can be configured as an input or an output.

(b) Pin 9 (Rs)A logic one on this pin disables the microcontroller and clears the contents of most registers. In other words, the positive voltage on this pin resets the microcontroller. By applying logic zero to this pin, the program starts execution from the beginning.

(c) Pin 10-17:port 3:Similar to port 1, each of these pins can serve as general input or output. Besides, all of them have alternative functions:

(d) Pin 10 Rxd Serial asynchronous communication input or Serial synchronous communication output.

(e) Pin 11 Txd Serial asynchronous communication output or Serial synchronous communication clock output.

(f) Pin 12 Int 0 Interrupt 0 input.

14

(g) Pin 13 Int 1 Interrupt 1 input.

(h) Pin 14 Counter 0 clock input.

(i) Pin 15 Counter 1 clock input.

(j) Pin 16 WR Write to external (additional) RAM.

(k) Pin 17 RD Read from external RAM.

(l) Pin 18,19 XT, X1Internal oscillator input and output. A quartz crystal which specifies operating frequency is usually connected to these pins. Instead of it, miniature ceramics resonators can also be used for frequency stability. Later versions of microcontrollers operate at a frequency of 0 Hz up to over 50 Hz.

(m) Pin 20 Ground.

(n) Pin 21-22 if there is no intention to use external memory then these port pins are configured as general inputs/outputs. In case external memory is used, the higher address byte, i.e. addresses A8-A15 will appear on this port. Even though memory with capacity of 64Kb is not used, which means that not all eight port bits are used for its addressing, the rest of them are not available as inputs/outputs.

(o) Pin 29 PenIf external ROM is used for storing program then a logic zero (0) appears on it every time the microcontroller reads a byte from memory.

(p) Pin 30 ALE prior to reading from external memory, the microcontroller puts the lower address byte (A0-A7) on P0 and activates the ALE output. After receiving signal from the ALE pin, the external register (usually 74HCT373 or 74HCT375 add-on chip) memorizes the state of P0 and uses it as a memory chip address. Immediately after that, the ALU pin is returned its previous logic state and P0 is now used as a Data Bus. As seen, port data multiplexing is performed by means of only one additional (and cheap) integrated circuit. In other words, this port is used for both data and address transmission.

(q) Pin 31 EA By applying logic zero to this pin, P2 and P3 are used for data and address transmission with no regard to whether there is internal memory or not. It means that even there is a program written to the microcontroller, it will not be executed. Instead, the program written to external ROM will be executed. By applying logic one to the EA pin, the microcontroller will use both memories, first internalthenexternal.

(r) Pin 32-39 Similar to P2, if external memory is not used, these pins can be used as general inputs/outputs. Otherwise, P0 is configured as address output (A0-A7) when the ALE pin is driven high (1) or as data output (Data Bus) when the ALE pin is driven low (0).

15

ARCHITECTURE OF AT89CS51:

FIG 4.3 Architecture of 8051 microcontroller

16

INTERRUPTS

The AT89C51 has in total of six interrupt sources, which means that it can recognize up to 6 different events that can interrupt regular program execution. Each of these interrupts can be individually enabled or disabled by setting bits of the IE register, whereas the whole interrupt system can be disabled by clearing the EA bit of the same register. Since this microcontroller has embedded Timer T2 and SPI (they don't fall under the “8051 Standard”) which can generate an interrupt, it was necessary to make some changes in registers controlling interrupt system. Besides, there is a new interrupt vector i.e. program memory address from which the program proceeds with execution when the Timer T2 generates an interrupt. All these changes are made on the previously unused bits. This enables all programs written for the previous versions of the microcontrollers to be used in this one too without being modified. This is why the 8051-based microcontrollers are so popular.

COUNTERS AND TIMERS

TIMERS T0 AND T1The AT89CS51 has three timers/counters marked as T0, T1 andT2. Timers T0 and T1

completely fall under the 8051 Standard. There are no changes in their operation.

TIMER T2Timer 2 is a 16-bit timer/counter installed only in new versions of the 8051 family.

Unlike timers T0 and T1, this timer consists of 4 registers. Two of them, TH2 and TL2, are connected serially in order to form a larger 16-bit timer register. Like timers 0 and 1, it can operate either as a timer or as an event counter. Another two registers, RCAP2H and RCAP2L, are also serially connected and operate as capture registers. They are used to temporarily store the contents of the counter register. The main advantage of this timer compared to timers 0 and 1 is that all read and swap operations are easily performed using one instruction. Similar to T0 and T1, it has four different modes of operation.

INPUT/OUTPUT PORTS (I/O PORTS)All 8051 microcontrollers have 4 I/O ports each comprising 8 bits which can be

configured as inputs or outputs. Accordingly, in total of 32 input/output pins enabling the microcontroller to be connected to peripheral devices are available for use. Pin configuration, i.e. whether it is to be configured as an input (1) or an output (0), depends on its logic state. In order to configure a microcontroller pin as an input, it is necessary to apply logic zero (0) to appropriate I/O port bit. In this case, voltage level on appropriate pin will be 0. Similarly, in order to configure a microcontroller pin as an input, it is necessary to apply a logic one (1) to appropriate port. In this case, voltage level on appropriate pin will be 5V (as is the case with any TTL input). This may seem confusing but don't lose your patience. It all becomes clear after studying simple electronic circuits connected to an I/O pin.

17

4.2.2 INFRARED PROXIMITY SENSOR

FIG 4.4 Infra-red sensor

This proximity detector using an infrared detector can be used in various equipment like

automatic door openers and burglar alarms. The circuit primarily consists of an infrared

transmitter and an infrared receiver. The transmitter section consists of a 555 timer IC

functioning in astable mode. It is wired as shown in the figure. The output from astable is fed to

an infrared LED via resistor R4, which limits its operating current. This circuit provides a

frequency output of 38 kHz at 50 per cent duty cycle, which is required for the infra-red

detector/receiver module. Siemens SFH5110-38 is a much better choice than SFH506-38.

Siemens SFH5110-38 is turned on by a continuous frequency of 38 kHz with 50 per cent duty

cycle, whereas SFH506 requires a burst frequency of 38k to sense. The receiver section

comprises an infrared receiver module, a 555 monostable multivibrator, and an LED indicator.

Upon reception of infrared signals, 555 timers (mono) turn on and remain on as long as infrared

signals are received. When the signals are interrupted, the mono goes off after a few seconds

(period=1.1 R7xC6) depending upon the value of R7-C6 combination. Thus if R7=470 kilo-

ohms and C6=4.7µF, the mono period will be around 2.5 seconds.

18

Both the transmitter and the receiver parts can be mounted on a single bread board or

PCB. The infrared receiver must be placed behind the infrared LED to avoid false indication due

to infrared leakage. An object moving nearby actually reflects the infrared rays emitted by the

infrared LED. The infrared receiver has sensitivity angle (lobe) of 0-60 degrees, hence when the

reflected IR ray is sensed, the mono in the receiver part is triggered. The output from the mono

may be used in any desired fashion. For example, it can be used to turn on a light when a person

comes nearby by energizing a relay. The light would automatically turn off after some time as

the person moves away and the mono pulse period is over. The sensitivity of the detector

depends on current-limiting resistor R4 in series with the infrared LED. Range is approximately

40 cm. For 20-ohm value of R4 the object at 25 cm can be sensed, while for 30-ohm value of R4

the sensing range reduces by 22.5 cm

.

FIG 4.6Graphical representation of basic principle of Infrared sensor

19

4.2.3 GSM module SIM900

FIG 4.7 GSM module SIM 900

The SIM900 E is a Tri-band GSM/GPRS solution in a compact plug-in module

integrated with a SIM card holder. Featuring an industry-standard interface, the SIM900 delivers

GSM/GPRS 900/1800/1900MHz performance for voice, SMS, Data, and Fax in a small form factor

and with low power consumption. The leading features of SIM300 E make it ideal for

virtually unlimited applications, such as WLL applications, M2M application, handheld devices

and much more.

20

Features

21

22

4.2.4 LCD 16x2 (JHD162A)

FIG 4.8 LCD 16x2LCD (Liquid Crystal Display) screen is an electronic display module and find a wide

range of applications. A 16x2 LCD display is very basic module and is very commonly used in various devices and circuits. These modules are preferred over seven segments and other multi segment LEDs. The reasons being: LCDs are economical; easily programmable; have no limitation of displaying special & even custom characters (unlike in seven segments), animations.

A 16x2 LCD means it can display 16 characters per line and there are 2 such lines. In this LCD each character is displayed in 5x7 pixel matrix. This LCD has two registers, namely, Command and Data.

The command register stores the command instructions given to the LCD. A command is an instruction given to LCD to do a predefined task like initializing it, clearing its screen, setting the cursor position, controlling display etc. The data register stores the data to be displayed on the LCD. The data is the ASCII value of the character to be displayed on the LCD. Click to learn more about internal structure of a LCD.

23

Pin Diagram: 

FIG 4.9 Pin out of LCD 16x2

Pin Description: 

Pin No Function Name

1 Ground (0V) Ground

2 Supply voltage; 5V (4.7V – 5.3V) Vcc

3 Contrast adjustment; through a variable resistor VEE

4 Selects command register when low; and data register when high Register Select

5 Low to write to the register; High to read from the register Read/write

6 Sends data to data pins when a high to low pulse is given Enable

7

8-bit data pins

DB0

8 DB1

9 DB2

10 DB3

11 DB4

12 DB5

13 DB6

14 DB7

15 Backlight VCC (5V) Led+

24

4.2.5 Battery& Battery Connector

FIG 4.10 Battery & Battery connector

1) Power supply:- 5V dc

2) 9V dc supply is used for fan(Testing instrument)

25

 4.3 SCHEMATICDIAGRAM:

FIG 4.11 Schematic diagram of microcontroller interfaced with LCD &

GSM module

26

CHAPTER: - 5

SOFTWARE DESCRIPTION

27

5.1 Eagle PCB design software

The eagle layout editor is an easy to use, yet powerful tool for designing printed circuit boards (pcbs). The name eagle is an acronym, which stands for easily applicable graphical layout editor.

Electrical wires are fixed onto the board, connecting a central processor to other components on the board. Nearly all electronic devices contain one or even more printed circuits boards.The award winning eagle is a powerful and flexible PCB design software offering high level functionality of expensive commercial circuit board design software at a fraction of the cost for over 20 years. 

Parameters and values can be entered in the eagle command line or, more conveniently, in the parameter toolbars which appear when a command is activated. As this is quite self-explanatory, the help text does not explicitly mention this option at other locations. Wherever coordinates or sizes (like width, diameter etc.) Can be entered, they may be given with units, as in 50mil or 0.8mm. If no unit is given, the current grid unit is used.

Eagle includes the following modules: schematic editor layout editor auto router

SCHEMATIC EDITOR

Automatic generation of supply connections Automatic board generation Electrical rule check (error check in the schematic and consistency check between schematic

and layout) User defined net classes for via size, wire width and clearance

28

Fig 5.1 Schematic editor & PCB layout editor

29

Fig 5.1 Schematic editor & PCB layout editor

LAYOUT EDITOR

Support of blind and buried via Rotation of objects in arbitrary angles  Components can be locked against moving Texts can be placed in any orientation

AUTOROUTER

Fully integrated into basic program User definable strategy by cost factors No placement restrictions

Fig 5.2 Auto routing in eagle software

30

CHAPTER:- 6

RESULTS

31

6.1ADVANTAGES:

1. Better performance and reliability.

2. Consumes less energy than conventional tachometer.

3. Portable so we can carry it to large rotating machine to note the rpm.

4. Hold the reading if hold key is pressed.

5. Measure accurately in the range of 10cm.

6. Light in weight as compared to the conventional tachometer.

7. Compact in size.

8. Simple circuitry and easy to understand.

9. Mass production may reduce the cost of Contact less tachometer.

10. Calibrations points are given to change the capacitance.

11. Easy to repair and can be extended to the wireless tachometer.

32

6.2 APPLICATION:

(a) This tachometer information is useful if your car has a standard shift transmission and you want to shift at the optimum tachometer RPM for best fuel economy or best acceleration. One of the least used gauges on a car with an automatic transmission. You should never race your engine so fast that the tachometer moves into the red zone as this can cause engine damage. Some engines are protected by the engine computer from going into the red zone. Usually, the tachometer shows single digit markings like 1, 2, 3 etc. Somewhere, you will also see an indicator that says RPM x 1000. This means that you multiply the reading by 1000 to get the actual RPM, so if the needle is pointing to 2, the engine is running at 2000 RPM.

(b) This can be used by the companies that prepare the fan. It can be used to check the performance of the fan.

(c) This can be used by the companies that manufacture motor that has the RPM. less than 9900 can use this device it shows the maximum and the average speed of the motor or rotating part.

(d) It can be used as optical counter just the thing is that the material to be counted should reflect the infrared radiation.

(e) It can be used to check the RPM for the hard disk drives, floppy disk drives in the field of electronics.

(f) When choosing a motorcycle tachometer there is a decent selection of manufacturers to choose from. Auto meter tachometers are brands that are well known. Each of these companies makes a quality Tach for bikes. Auto meter makes Tach's for cars and has expanded to making them for motor cycles as well. This line is called Pro-Cycle. When it comes to choosing the right Tach it is important to keep in mind the application that you are going to use it for. They are fairly easy to install and have a range of up to 9,000 RPM. Since most bikes have high revving engines it is important to find one that suits your application. Auto meter Tachometers are mostly electronic and come in a variety of sizes and variations. There is bound to be one that suits your application. Autometer also makes tachometers that have integrated shift lights or you can buy the shift light kit by itself. In order to use a shift light you will also need a RPM activated module and a RPM Pill module kit. You can also choose from a black or white face as well as the diameter of the gauge. Lightning Performance makes a pretty cool looking electronic tachometer. I am currently of currently aware of 3 different Lightning Performance tach's. They are all micro gauges and areeasily mounted on to a handlebar. They integrate very well in to most motor cycle’s lines. Lightning Performance Electronic tachometers are CNC machined from a 5 lb. brick of billetAluminum which is then chrome plated for a show quality finish.

33

6.3 CONCLUSION:

Thus by using this project, We can get accurate REVOLUTION PER MINUTES (RPM) ,

protect our rotating equipment & Also get the RPM reading on mobile through GSM.

6.4 PLAN FOR NEXT SEMESTER :

34

PCB DESIGN

CODING

HARDWARE IMPLEMENTATION

TESTING & TROUBLESHOOTING

FINAL PROJECT REPORT

CHAPTER:- 7

BIBLIOGRAPHY

35

References

1. www.wikipedia.com

2. www.google.com

3. www.seminarprojects.com/wirelessnotice-board

4. www.atmel.com/piccontroller

5. www.electronics4you.com/leddisplaynoticeboard

6. www.electronicsprojects.com/gsmbasedlcdnotice

7. www.datasheetsarchive.com/datasheets

8. www.eagle.com/eaglesoftware

9. www.alldatasheets.com/view.jsp?Searchword=8051

10. www.projectworld.com

11. www.allabout8051.com

12. Programming and Customizing the PIC Microcontroller by MykePredko - Third Edition

13. Making PIC Microcontroller Instruments &ControllersbyHarprit Singh Sandhu

36

APPENDIX - I

37

APPENDIX – II

38

APPENDIX - III

39