WIRLESS INDUSTRIAL AUTOMATION SYSTEM USING RF

WIRELESS INDUSTRIAL AUTOMATION SYSTEM USING RF Chapter 1 Introduction

In this competitive world, human cannot spare his time to perform his daily activities manually without any fail. The most important thing he forgets is to switch off the room lights wherever not required. With this, even the power will be wasted up to some extent. This project gives the best solution for electrical power wastage. Also the manual operation is completely eliminated. The home appliances can be switched on/off using RF without actually going near the switch boards or regulators. One of wireless communication system is RF (Radio frequency) communication system as it is very cheap and very easy to implement. The electrical appliances can be switched on/off using this RF concept without actually going near the switch boards or regulators. The loads like lights, motors, heaters, power controlling system and also current through the loads can be controlled in this project. We can control all loads at a time from one place (control room) without connecting any physical wire between loads and control room. The RF modules used here are STT-433 MHz Transmitter, STR-433 MHz Receiver, HT640 RF Encoder and HT648 RF Decoder. Switches are provided at the transmitter end, to control the loads which are connected at the receiver side. The switches are interfaced to the RF transmitter through RF Encoder. The encoder continuously reads the status of the switches, passes the data to the RF transmitter and the transmitter transmits the data.

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At the receiving end, the RF receiver receives this data, gives it to RF decoder. This decoder converts the single bit data into 8-bit data and presents it to the microcontroller. Now, it is the job of the controller to read the data and perform the corresponding action i.e., switch on/off corresponding load according to the user requirement. 1.1 Objective of the project The project aims at controlling the electrical appliances in the homes using RF communication. The project uses the RF technology and Embedded Systems to design this application. The main objective of this project is to design a system that continuously checks for the data received from the transmitter section and changes the status of the loads accordingly by use of a microcontroller based control system. It consists of a switch control module, RF transmitter and receiver section, microcontroller and the loads at the receiver side. This project is a device that collects data from the transmitting section, codes the data into a format that can be understood by the controlling section. This receiving section controls the electrical appliances as per the command received from the transmitter section.

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Chapter 2 Hardware, Software Implementation &working procedure

2.1 Project Design Project design includes an array of activities from generating ideas to planning how these ideas could become a realizable project..Project design is very broad in scope and includes everything that must be determined before a project can proceed. That is, what the project suppose to accomplish? Who will found the project? Who will do the project? Who will prepare the technical design, ordering of materials, budgeting, managing, etc The implementation of the project design can be divided in two parts. Hardware implementation Firmware implementation Hardware implementation deals in drawing the schematic on the plane paper according to the application, testing the schematic design over the breadboard using the various ICs to find if the design meets the objective, carrying out the PCB layout of the schematic tested on breadboard, finally preparing the board and testing the designed hardware. The firmware part deals in programming the microcontroller so that it can control the operation of the ICs used in the implementation. In the present work, we have used the Orcad design software for PCB circuit design, the Keil v3 software development tool to write and compile the source code, which has been written in the C language. The Proload programmer has been used to write this compile code into the microcontroller. The firmware implementation is explained in the next chapter.

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2.1.1 Block Diagram of the Wireless Industrial Automation System The block diagram of the design is as shown in below fig. It consists of mainly transmitter section and the receiver section.

TRASMITTE R SECTION

DATA TRANSMISSION

RECEIVER SECTION

Transmitter Section: Transmitter section is mainly consists of power supply, RF Encoder HT12D, RF transmitter SST-433 switches. Transmitter section is mainly used to transmit the data from transmitter. It is acts like a remote in this project.

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2.2 Power Supply:

The input to the circuit is applied from the regulated power supply. The a.c. input i.e., 230V from the mains supply is step down by the transformer to 12V and is fed to a rectifier. The output obtained from the rectifier is a pulsating d.c voltage. So in order to get a pure d.c voltage, the output voltage from the rectifier is fed to a filter to remove any a.c components present even after rectification. Now, this voltage is given to a voltage regulator to obtain a pure constant dc voltage.

Transformer:
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Usually, DC voltages are required to operate various electronic equipment and these voltages are 5V, 9V or 12V. But these voltages cannot be obtained directly. Thus the a.c input available at the mains supply i.e., 230V is to be brought down to the required voltage level. This is done by a transformer. Thus, a step down transformer is employed to decrease the voltage to a required level. Rectifier: The output from the transformer is fed to the rectifier. It converts A.C. into pulsating D.C. The rectifier may be a half wave or a full wave rectifier. In this project, a bridge rectifier is used because of its merits like good stability and full wave rectification.

Filter: Capacitive filter is used in this project. It removes the ripples from the output of rectifier and smoothens the D.C. Output received from this filter is constant until the mains voltage and load is maintained constant. However, if either of the two is varied, D.C. voltage received at this point changes. Therefore a regulator is applied at the output stage.

Voltage regulator: As the name itself implies, it regulates the input applied to it. A voltage regulator is an electrical regulator designed to automatically maintain a constant voltage level. In this project, power supply of 5V and 12V are required. In order to obtain these voltage levels, 7805 and 7812 voltage regulators are to be used. The first number 78 represents positive supply and the numbers 05, 12 represent the required output voltage levels.

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2.4 RF TRANSMITTER STT-433MHz:

The STT-433 is ideal for remote control applications where low cost and longer range is required. The transmitter operates from a 1.5-12V supply, making it ideal for battery-powered applications. The transmitter employs a SAW-stabilized oscillator, ensuring accurate frequency control for best range performance. Output power and harmonic emissions are easy to control, making FCC and ETSI compliance easy. The manufacturing-friendly SIP style package and low-cost make the STT-433 suitable for high volume applications.

ABOUT THE TRANSMITTER: The STT-433 is ideal for remote control applications where low cost and longer range is required. The transmitter operates from a1.5-12V supply, making it ideal for battery-powered applications. The transmitter employs a SAW-stabilized oscillator, ensuring accurate frequency control for best range performance. The manufacturing-friendly SIP style package and low-cost make the STT-433 suitable for high volume applications.

PIN DESCRIPTION:

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GND: Transmitter ground. Connect to ground plane DATA: Digital data input. This input is CMOS compatible and should be driven with CMOS level inputs. VCC: Operating voltage for the transmitter. VCC should be bypassed

with a .01uF ceramic capacitor and filtered with a 4.7uF tantalum capacitor. Noise on the power supply will degrade transmitter noise performance. ANT: 50 ohm antenna output. The antenna port impedance affects

output power and harmonic emissions. Antenna can be single core wire of approximately 17cm length or PCB trace antenna. ENCODER HT ht12E:

HT12E is an encoder integrated circuit of 212 series of encoders. They are paired with 212 series of decoders for use in remote control system applications. It is mainly used in interfacing RF and infrared circuits. The chosen pair of encoder/decoder should have same number of addresses and data format. Simply put, HT12E converts the parallel inputs into serial output. It encodes the 12 bit parallel data into serial for transmission through an RF transmitter. These 12 bits are divided into 8 address bits and 4 data bits.

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HOW DOES THE ENCODER WORK?

Address/data programming (preset) The status of each address/data pin can be individually pre-set to logic high or low. If a transmission enable signal is applied, the encoder scans and transmits the status of the 12 bits of address/data serially in the order A0 to AD11 for the HT12E encoder and A0 to D11 for the HT12A encoder. During information transmission these bits are transmitted with a preceding synchronization bit. If the trigger signal is not applied, the chip enters the standby mode and consumes a reduced current of less than 1mA for a supply voltage of 5V. Usual applications preset the address pins with individual security codes using DIP switches or PCB wiring, while the data is selected by Department of Electronics and Communication Engineering. TKRCET Page 10

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push buttons or electronic switches. For the HT12E encoders, transmission is enabled
by applying a low signal to the TE pin.

The address pins of the encoder are joined with controllers port 0. The data pins of the encoder are linked with controllers port P2.0 to P2.3.Once the data and address are set by the controller, the transmission enable pin of the encoder connected with the pin P2.4 of the controller is set to LOW. Thus enabling the transmission, the data is sent to the RF transmitter module, transmitting the signal continuously till the transmission enable pin set to HIGH.
Transmission enable For the HT12E encoders, transmission is enabled by applying a low signal to the TE pin. For the HT12A encoders, transmission is enabled by applying a low signal to one of the data pins D8~D11.

FLOW CHART:

ALGORITHM: STEP1: power at the receiver section is on.

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Step2: Untill
mode and voltage of 5V

the trigger signal applied the system goes into stand by

consumes a reduced current of less than 1mA for a supply

Step3: If the TE signal is enabled and the trigger signal is applied then the
transmitter sends 4 DATA words else it goes to power on stage.

Step4: still if the TE signal is enabled then again the transmitter transmits 4
DATA words continuously and this process repeats if the TE signal still enabled. How to select the resistance value to be connected to the oscillator of the encoder: By drawing a graph between the oscillator frequency and supply voltage we can select the required resistance at the oscillator.The graph shown abovbelow decides the resistance value to be connected to the oscillator pins of the encoder. The oscillator resistance will have an effect on startup time and steady state amplitude. For the data communication at a particular frequency in the RF range, both the transmitter and receiver should be set to a particular frequency. The exact setting of the frequency can be obtained in the encoder and decoder circuits. The frequency value can be set using the graph. The operating voltage of encoder and decoder is 5V. Thus looking at the graph at 5V VDD, if we select the frequency in the range of 1.25 and 1.50 we are selecting 220k resistance.

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BASIC APPLICATION CIRCUIT OF HT12E

ENCODER:

The data sent from the microcontroller is encoded and sent to RF transmitter. The data is transmitted on the antenna pin. Thus, this data should be received on the destination i.e, on RF receiver. This application circuit is shown below.

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Receiver Section: Receiver section is mainly consist of microcontroller 8051, RF receiver STR_433, RF decoder HT_12E, crystal oscillator and loads.

2.3 Microcontrollers:
Microprocessors and microcontrollers are widely used in embedded systems products. Microcontroller is a programmable device. A microcontroller has a CPU in addition to a fixed amount of RAM, ROM, I/O ports and a timer embedded all on a single chip. The fixed amount of on-chip ROM, RAM and number of I/O ports in microcontrollers makes them ideal for many applications in which cost and space are critical. The Intel 8051 is Harvard architecture, single chip microcontroller (C) which was developed by Intel in 1980 for use in embedded systems. It was popular in the 1980s and early 1990s, but today it has largely been superseded by a vast range of enhanced devices with 8051-compatible processor cores that are manufactured by more than 20 independent manufacturers including Atmel, Infineon Technologies and Maxim Integrated Products.

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8051 is an 8-bit processor, meaning that the CPU can work on only 8 bits of data at a time. Data larger than 8 bits has to be broken into 8-bit pieces to be processed by the CPU. 8051 is available in different memory types such as UV-EPROM, Flash and NVRAM.

2.5 RF RECEIVER STR-433 MHz:

The 433 MHz RF Receiver is ideal for short-range remote control applications where cost is a primary concern. The receiver module requires no external RF components except for the antenna. It generates virtually no emissions making FCC and ETSI approvals easy. The super regenerative design exhibits exceptional sensitivity at a very low cost. The manufacturing friendly SIP style package and low-cost make the433 Receiver suitable for high volume applications.

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The data is received by the RF receiver from the antenna pin and this data is available on the data pins. Two Data pins are provided in the receiver module. Thus, this data can be used for further applications.

PIN DESCRIPION
ANT: Antenna input. GND: Receiver Ground. Connect to ground plane. VCC (5V): VCC pins are electrically connected and provide operating voltage for the receiver. VCC can be applied to either or both. VCC should be bypassed with a .1F ceramic capacitor. Noise on the power supply will degrade receiver sensitivity. DATA: Digital data output. This output is capable of driving one TTL or CMOS load. It is a CMOS compatible output. Similarly, as the transmitter requires an encoder, the receiver module requires a decoder. The decoder used is HT12dL from HOLTEK SEMICONDUCTOR INC. HOW DOES THE DECODER WORK? The 2 series of decoders provides various combinations of addresses and data pins in different packages so as to pair with the 212 series of encoders. The decoders receive data that are transmitted by an encoder and interpret the first N bits of code period as addresses and the last 12-N bits as data, where N is the address code number. A signal on the DIN pin activates Department of Electronics and Communication Engineering. TKRCET Page 16

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the oscillator which in turn decodes the incoming address and data. The decoders will then check the received address three times continuously. If the received address codes all match the contents of the decoder local address, the 12-N bits of data are decoded to activate the output pins and the VT pin is set high to indicate a valid transmission. This will last unless the address code is incorrect or no signal is received. The output of the VT pin is high only when the transmission is valid. Otherwise it is always low. FLOW CHART:

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ALGORITHM: Step1: As the power is on at the receiver section.

Step2: until the trigger signal is received the receiver section is in the stand
by mode.

Step3: once the code is received from the transmitter

then it checks the

received address with the local address of decoder if the code is matched then receiver store the data else it goes to the power on mode.

Step4: If the data still receiving from the transmitter then again the
received address is again checked with the local address of decoder for the 3 times and store the data else again goes to previous stage and waits their until the data received.

Step5: After the data is completely received then the pin VT is activated
which is indicating that valid transmission. Once the pin VT is disabled then the decoder will ignore all words coming to it. BASIC APPLICATION CIRCUIT OF HT12D DECODER: The data sent from the transmitter is received at the receiver section which is shown in the below fig. as the loads connected to the receiver are controlled through the switches connected at the transmitter section.

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2.6 Switches and Pushbuttons

This is the simplest way of controlling appearance of some voltage on microcontrollers input pin. There is also no need for additional explanation of how these components operate.

This is about something commonly unnoticeable when using these components in everyday life. It is about contact bounce, a common problem with mechanical switches. If contact switching does not happen so quickly, several consecutive bounces can be noticed prior to maintain stable state. The reasons for this are: vibrations, slight rough spots and dirt. Anyway, this whole process does not last long (a few micro- or milliseconds), but long enough to be registered by the microcontroller. Concerning the pulse counter, error occurs in almost 100% of cases.

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The simplest solution is to connect simple RC circuit which will suppress each quick voltage change. Since the bouncing time is not defined, the values of elements are not strictly determined. In the most cases, the values shown on figure are sufficient. If complete safety is needed, radical measures should be taken. The circuit (RS flip-flop) changes logic state on its output with the first pulse triggered by contact bounce. Even though this is more expensive solution (SPDT switch), the problem is definitely resolved. Besides, since the condensator is not used, very short pulses can be also registered in this way. In addition to these hardware solutions, a simple software solution is also commonly applied. When a program tests the state of some input pin and finds changes, the check should be done one more time after certain time delay. If the change is confirmed, it means that switch (or pushbutton) has changed its position. The advantages of such solution are: it is free of charge, effects of disturbances are eliminated and it can be adjusted to the worst-quality contacts.

2.7 TRIAC BT136

General Description Glass passivated, sensitive gate triacs in a plastic envelope, intended for use in general purpose bidirectional switching and phase control applications, where high voltages sensitivity is required in all four quadrants.

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.2.8 BATTERY: 9V Battery is sufficient to power up the RF transmitter and the remaining devices in the transmitter section. Since the receiver section involves the microcontroller, a regulated power supply is preferred for the safe operation of the microcontroller.

2.9 LCD
LCD screen consists of two lines with 16 characters each. Each character consists of 5x7 dot matrix. Contrast on display depends on the power supply voltage and whether messages are displayed in one or two lines. For that reason, variable voltage 0-Vdd is applied on pin marked as Vee. Trimmer potentiometer is usually used for that purpose. Some versions of displays have built in backlight (blue or green diodes). When used during operating, a resistor for current limitation should be used (like with any LE diode).

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LCD Basic Commands All data transferred to LCD through outputs D0-D7 will be interpreted as commands or as data, which depends on logic state on pin RS: RS = 1 - Bits D0 - D7 are addresses of characters that should be displayed. Built in processor addresses built in map of characters and displays corresponding symbols. Displaying position is determined by DDRAM address. This address is either previously defined or the address of previously transferred character is automatically incremented. RS = 0 - Bits D0 - D7 are commands which determine display mode. List of commands which LCD recognizes are given in the table below: Execution

Command Clear display Cursor home Entry mode set Display on/off control Cursor/Display Shift Function set Set CGRAM address

RS RW D7 D6 D5 D4 D3 D2 D1 D0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 1 0 1 I/

Time 1 1.64mS x 1.64mS

S 40uS D 0 0 1 D U B 40uS 0 1 D/C R/L x x 40uS 1 DL N F x x 40uS CGRAM address 40uS

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Set DDRAM address Read BUSY flag (BF) Write to CGRAM DDRAM Read from DDRAM CGRAM

0 0 or or 1 1

0 1 0 1

1 DDRAM address BF DDRAM address

40uS -

D7 D6 D5 D4 D3 D2 D1 D0 40uS D7 D6 D5 D4 D3 D2 D1 D0 40uS

I/D 1 = Increment (by 1) 0 = Decrement (by 1) S 1 = Display shift on 0 = Display shift off D 1 = Display on 0 = Display off U 1 = Cursor on 0 = Cursor off B 1 = Cursor blink on 0 = Cursor blink off

R/L 1 = Shift right 0 = Shift left DL 1 = 8-bit interface 0 = 4-bit interface N 1 = Display in two lines 0 = Display in one line F 1 = Character format 5x10 dots 0 = Character format 5x7 dots D/C 1 = Display shift 0 = Cursor shift

Firmware Implementation of the project design

This chapter briefly explains about the firmware implementation of the project. The required software tools are discussed in section 4.2. Section 4.3 shows the flow diagram of the project design. Section 4.4 presents the firmware implementation of the project design.

2.10 Software Tools Required

Keil v3, Proload are the two software tools used to program microcontroller. The working of each software tool is explained below in detail. 2.10.1 Programming Microcontroller
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A compiler for a high level language helps to reduce production time. To program the AT89S52 microcontroller the Keil v3 is used. The programming is done strictly in the embedded C language. Keil v3 is a suite of executable, open source software development tools for the microcontrollers hosted on the Windows platform. The compilation of the C program converts it into machine language file (.hex). This is the only language the microcontroller will understand, because it contains the original program code converted into a hexadecimal format. During this step there are some warnings about eventual errors in the program. This is shown in Fig 4.1. If there are no errors and warnings then run the program, the system performs all the required tasks and behaves as expected the software developed. If not, the whole procedure will have to be repeated again. Fig 4.2 shows expected outputs for given inputs when run compiled program. One of the difficulties of programming microcontrollers is the limited amount of resources the programmer has to deal with. In personal computers resources such as RAM and processing speed are basically limitless when compared to microcontrollers. In contrast, the code on microcontrollers should be as low on resources as possible.

Keil Compiler:
Keil compiler is software used where the machine language code is written and compiled. After compilation, the machine source code is converted into hex code which is to be dumped into the microcontroller for further processing. Keil compiler also supports C language code.

Pro load:
Proload is software which accepts only hex files. Once the machine code is converted into hex code, that hex code has to be dumped into the microcontroller and this
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is done by the Proload. Proload is a programmer which itself contains a microcontroller in it other than the one which is to be programmed. This microcontroller has a program in it written in such a way that it accepts the hex file from the Keil compiler and dumps this hex file into the microcontroller which is to be programmed. As the Proload programmer kit requires power supply to be operated, this power supply is given from the power supply circuit designed above. It should be noted that this programmer kit contains a power supply section in the board itself but in order to switch on that power supply, a source is required. Thus this is accomplished from the power supply board with an output of 12volts.

Features

Supports major Atmel 89 series devices Auto Identify connected hardware and devices Error checking and verification in-built Lock of programs in chip supported to prevent program copying 20 and 40 pin ZIF socket on-board Auto Erase before writing and Auto Verify after writing Informative status bar and access to latest programmed file Simple and Easy to use Works on 57600 speed

Programming Software Computer side software called 'Proload V4.1' is executed that accepts the Intel HEX format file generated from compiler to be sent to target microcontroller. It auto detects the hardware connected to the serial port. It also auto detects the chip inserted and

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bytes used. Software is developed in Delphi 7 and requires no overhead of any external DLL.

2.11 Working procedure:

RF based industrial automation system is an exclusive project in which the status of the electrical loads can be controlled using RF technology. The RF transmitter serves as the RF remote in this project. The transmitter section consists of the switches using which the loads at the receiver section can be controlled. The RF receiver, the power supply section, the controller section and the electrical loads constitute the receiver section. Thus, when the user presses a switch at the transmitter side, the RF transmitter transmits this signal. At the other end, the RF receiver receives this signal, decodes the signal and passes this data to the microcontroller. Thus, based on the signal received, the microcontroller changes the status of the loads. Since the microcontroller cannot drive the devices that run with AC supply, TRIAC is used to control the devices and it acts as an interface between the microcontroller and the load.
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3.1 Advantages
Cost effective User friendly The RF receiver and transmitter work perfectly even in uneven weather conditions

3.4 Applications
This project can be used to control the electrical appliances in the homes and industries.

Chapter 3 Results and Conclusions 3.2 Conclusion

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The implementation of RF based industrial automation system is done successfully. The communication is properly done without any interference between different modules in the design. Design is done to meet all the specifications and requirements. Software tools like Keil Uvision Simulator, Proload to dump the source code into the microcontroller, Orcad Lite for the schematic diagram have been used to develop the software code before realizing the hardware. Continuously reading the commands from the transmitter and change the status of the particular load specified by the user at the transmitter side accordingly is the main job carried out by the microcontroller. The mechanism is controlled by the microcontroller. Circuit is implemented in Orcad and implemented on the microcontroller board. The performance has been verified both in software simulator and hardware design. The total circuit is completely verified functionally and is following the application software. It can be concluded that the design implemented in the present work provide portability, flexibility and the data transmission is also done with low power consumption.

3.3 Results
Assemble the circuit on the PCB as shown in Fig 5.1. After assembling the circuit on the PCB, check it for proper connections before switching on the power supply.

3.5 References
1. http://www.privateline.com/PCS/Weisman.pdf 2. http://focus.ti.com/lit/ml/slap127/slap127.pdf 3. http://www.sunrom.com/files/STT-433.pdf 4. http://www.sunrom.com/files/STR-433.pdf
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5. http://www.zntu.edu.ua/base/lection/rpf/lib/zhzh03/8051_tutorial.pdf 6. http://www.atmel.com/dyn/resources/prod_documents/doc1919.pdf 7. http://www.doctronics.co.uk/ldr_sensors.htm 8. http://www.technologystudent.com/elec1/ldr1.htm 9. http://www.physics.iitm.ac.in/courses_files/courses/eleclab03_odd/light_depende nt_resistor.htmhttp://www.national.com/ds/LM/LM35.pdf 10. http://www.ladyada.net/learn/sensors/tmp36.html

11. http://www.taltech.com/TALtech_web/resources/intro-sc.html

12. http://focus.ti.com/lit/ds/symlink/max232.pdf 13. http://www.kmitl.ac.th/~kswichit/89prog/index.html 14. http://www.microdigitaled.com/8051/Software/keil_tutorial.pdf

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