Wireless Cranes Using 8051 Project Report

Industrial remote bridge crane & hoist control system
CHAPTER-1 Abstract
With the advancement of technology today wireless has become a part of mans life. The present project introduces the concept of remote bridge cranes & hoist control through RF. The overall system is designed with microcontroller to make the system more effective and efficient. Utilization of microcontroller in field of industrial bridge cranes is gaining popularity for several reasons including price, programmability and performance specifications offered. Software development rather than hardware development increasingly dominates the new product design cycles. Therefore this is one of the most common reasons as to why designers choose microcontroller and its architecture. It also has rich and cost effective software. Our project mainly focuses to introduce wireless (remote) in controlling cranes & hoist to minimize human load. The whole project is based on Industrial remote bridge cranes and hoist control systems. To show that the concept can be successfully implemented we have built a prototype module. This report goes on to explain as to how the prototype could be developed, the working of the prototype and the logic behind it. But, before going deep into its details we go on to explain the overview of this project in the following paragraphs of this section. The prototype of this project basically consists of 3 parts 1. A portable transmitter unit, 2. Receiving unit 3. Relays electrically connected to the motor Here transmitter generates and transmits control signals. Receiving equipment permanently installed on the crane and electrically connected to the crane's motor controllers. A switch on the transmitter controls all functions of the motor.
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Each switch on the remote controller generates a unique combination of pulses that are transmitted to the crane-mounted receiver via a radio signal. At the crane, the pulse strings are removed from the carrier signal to activate the desired motor controllers. The receiving equipment cabinet contains circuitry for decoding the radio signal generated by the controller, and drivers that extract the pulse codes from the incoming signal and convert them into signals suitable for the crane's motor controllers. Radio control allows the operator to get the best line of sight possible for operations. Pendant control requires two persons for many lifts. Radio lets one person do the same lifts, and do them better. On pendant, a lot of time was wasted walking back and forth to get to the spot where the pendant could be operated. Sometimes the operator had to climb over stuff to hang onto the pendant. Now, the operator has the freedom to be where best to handle the load. On pendant, an operator was sometimes forced into awkward moves in tight areas, even right under the load. Radio lets the operator take the safest path on the floor. Just having a pendant hanging down is a hazard in itself, both to personnel and the pendant. Crane operators are working all the time: the radio makes their job easier. At peak periods when there are temporary workers, they can learn radio operation much faster than pendant control.
CHAPTER-2 INTRODUCTION:
The project report describes about design, development and fabrication of one demonstration unit of the project work INDUSTRIAL REMOTE BRIDGE CRANE AND HOIST CONTROL SYSTEM followed by a detailed discussion of design consideration and design verification. The description is based on the prototype module developed for demonstration purpose. Crane operation has always had two simply stated objectives: get the crane to the load, then move the load somewhere; and do it safely and efficiently. In the past, crane movements were actuated either by a cab-mounted operator guided by hand signals from a floor walker, or by pushbutton pendants hanging from the crane and controlled by someone on the floor. Today, a third method has entered the scene: remote control of a crane's operation, particularly through radio signals, is finding more and more popularity, because it overcomes so many of the practical problems of crane operation and control. Consider This: The cab-mounted operator's primary job is to move the crane. That person may be able to work alone managing some operations with below-the-hook attachments, such as magnets, grabs, or C-hooks. But the vast majority of loads require assistance on the floor both for rigging and positioning direction. Both activities slow crane movement and may involve some safety hazards. While pendant control solves some of these problems by bringing crane control closer to the load, there are still problems. The pendant is on the wrong side of the crane half the time, even with the convenience of festooning across the bridge. Or the pendant could be dropped from the hoist. Either way, the operator finds that dodging the load and untangling the cable become time-consuming and somewhat hazardous parts of the job. While a floor walker directing the operator with hand signals or voice radio simplifies the job, crane movement would still be slowed to the operators pace. And a walking aisle must also be available. Most of these problems are avoided using a remote cordless control because it permits the operator to control the crane's position from any point on the floor that makes most sense for safety and efficiency - at
the left of the load, on the truck, in the railcar, behind the load, or on the rack or shelving. This makes more efficient use of both the operator's and the crane's time.
The Remote Controller

A remote control system consists of a portable transmitter unit that generates control signals, plus receiving equipment permanently installed on the crane and electrically connected to the crane's motor controllers. Switches on the transmitter control all functions of the crane. Installation may be as a retrofit to an existing crane, or as part of a new construction. Each switch on the remote controller generates a unique combination of pulses that are transmitted to the cranemounted receiver via a radio signal. At the crane, the pulse strings are removed from the carrier signal to activate the desired motor controllers. The response time for the electronics, for all practical purposes, is instantaneous. The receiving equipment cabinet contains circuitry for decoding the radio signal generated by the controller, and drivers that extract the pulse codes from the incoming signal and convert them into signals suitable for the crane's motor controllers Benefits of remote cordless controls Remote crane control may not be for every situation; the following key areas need to be evaluated. Duty cycle: Cranes that are in operation 20% to 80% of the time have an inherent inefficiency in that the cab operator is idle for a great part of his shift. By placing the person on the floor with a remote controller, he or she is available for the other duties when the crane is in active. Duties of floor person: If the hooking operation is relatively simple so that one person can operate the crane with a remote controller and also handle
the hooking, great benefits are realized. Here, too, if the duty cycle is less than continuous, a remote control unit makes it possible for the floor person to perform other duties between cycles. Visibility: Can the operator see from the cab or handle rigging from the pendant location? Are voice and hand signals needed? If so, a remote cordless controller can improve efficiency by eliminating such intermediaries. Crane operation will be faster, and manpower savings are realized if a relay person/rigger can be reassigned. Materials being handled: Are the items being moved expensive: finished products such as steel rolls or dies? Can inaccurate hooking and spotting damage the materials? If so, the cordless control unit will put the operator up close where the person can be most accurate and cause least damage. Location of cab: Must the cab be positioned in hot areas or over such dangerous locations as soaking pits, or tilting ladles? Can the crane be operated from a safer location? If heat is the problem, will operating the crane from a remote location eliminate need for air conditioning? Use of materials or machines: Are men and machines dependent upon operation of the crane; must they frequently wait for an operator? If so, will use of a remote controller eliminate the tie-up?
CHAPTER-3 BLOCK DIAGRAM:

Industrial Remote Bridge Crane and Hoist Control system has 3 Modules
Hand Held Device Device Controller 4 channel Relay
Hand Held Device:

Hand Held Device is used to select and control the operation. Such as Up, Down, forward and reverse. Hand Held Device transmits an encoded data to Device Controller based on user Interface Button operations. This module consists of the following block. User Interface (Keypad) RF Encoder RF Transmitter
Block Diagram (Hand held Remote Control):
SWITCH 1
SWITCH 2 ENCODER SWITCH 3
RF Transmitter Module
9 Volt Battery SWITCH 4
Data Encoder: Here the encoder is used to encode the data (Pressed Switch). This encoded data is fed to RF Transmitter which continuously transmits this encoded data. RF Transmitter: RF Transmitter sub module uses TLP434a ASK Digital Modulator. The data stream to ASK Modulator is given using 89C52 on-chip UART operating at a baud rate of 2400 bps. TLP-A Series: The "A" Series transmitter modules, based on ASK modulation, with an output of up to 8mW depending on power supply voltage. The TLP transmitter is based on SAW resonator and accepts both linear and digital inputs. The transmitter TLP's output is up to 8mW with a range of
approximately 400-foot (open area) outdoors.
Indoors, the range is
approximately 200 foot. The TLP transmitter accepts both linear and digital inputs can operate from 1.5 to 12 Volts-DC, and makes building a miniature hand-held RF transmitter very easy. Amplitude Shift Keying This is the type of modulation where no carrier is present in the transmission of a zero.
Device Controller:
Device Controller has the following Sub Modules AT89S52 Microcontroller RF Receiver Output Control
Device Controller receives the encoded data from Handheld Device through RF Receiver sub module, decodes and identifies the device to be controlled. It uses output control sub module to control the appliances.
BLOCK DIAGRAM
Display
RF Receiver
Microcontroller
DC DC Motor1 Motor1
Decoder
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4 Relay s
DC DC Motor2 Motor2 Page 9
Data Decoder: The Data decoder is used to decode unknown noisy version of encoded data. The encoded data is initially caught by the RF receiver. This receiver passes on the data to decode the encoded data. User Interface: User Interface Module consists of 16X2 LCD and Menu Buttons.
LCD
When user presses Button, LCD shows the operation that is controlled. The controller operations are Moving forward Moving reverse Moving Up
Moving down
RF Receiver: RF Transmitter sub module uses RLP434a ASK Digital demodulator. The data stream from ASK demodulator.
RLP-A Series: The "A" Series Receiver modules are based on ASK modulation and the receiver RLP has a sensitivity of 3uV. It operates from 4.5 to 5.5 volts-DC, and has both linear and digital outputs. For maximum range, we recommend antenna length to be 1/4 wave of the frequency. That means, for 433.92 MHz, the antenna length is approximately 17cm long.
CHAPTER -4 CIRCUIT DIAGRAM & ANALYSIS:

Transmitter Side:
RF TRANSMITT ER
Transmitter Tools: RF_TX_315MHz:

Label DATA VCC GND ANT Description The Data pin of the transmitter. The power supply of the transmitter. The ground of transmitter. The hole to solder and connect antenna. (Please select the correct antenna length, which is 24cms.)
Features:
Complete RF Transmitter Module no external components and no tuning required. High Performance SAW Based Architecture with a Maximum Range of 100 feet at 4800 bps data rate.
Interface directly to Encoders and Microcontrollers with ease. Low Power Consumption suitable for battery operated devices.
Encoder TX HT 640
Operating voltage: 2.4V~12V. Low power and high noise immunity CMOS Technology. Low standby current. Three words transmission. Built-in oscillator needs only 5% resistor.
Easy interface with an RF or infrared transmission media. Minimal external components
Transmitter Analysis:
The transmitter is a battery operated frequency modulation radio transmitter. Incorporated with the transmitter is an antenna, encoder and disposal battery. Transmitter carrier frequency is crystal controlled. When the various switches are actuated, encoded control signals are sent to the RF transmitter via the antenna.
Encoder:
We use 318 encoders are a series of CMOS LSIs for remote control system applications. They are Capable of encoding 18 bits of information which consists of N address bits & 18_N data bits. Each address/data input is externally ternary programmable if bonded out. It is otherwise set floating internally. The programmable address/data is transmitted together with the header bits via an RF transmission medium upon receipt of a trigger signal. The capability to select a TE trigger type or a DATA trigger type further enhances the application flexibility of the 3 18 series of encoders.
Operation:
The 318 series of encoders begins a three-word transmission cycle upon receipt of a transmission enable(TE for the HT640 active high).This cycle will repeat itself as long as the transmission is enable (TE or D12~D17) is held high. Once the transmission enable falls low, the encoder output completes its final cycle and then stops as shown below:
Address/Data programming (Preset):

The status of each address/data pin can be individually preset to logic high, low, or floating. If a transmission enable signal is applied, the encoder scans and transmits the status of the 18 bits of address/data serially in the order A0 to AD17 for the HT640. The address pins are usually preset to transmit data codes with particular security codes by the DIP switches or PCB wiring, while the data is selected using push buttons or electronic switches.
Transmissions enable:
For the TE trigger type of encoders, transmission is enabled by applying a high signal to the TE pin. But for the Data trigger type of encoders, it is enabled by applying a high signal to one of the data pins D12~D17.
FLOW CHART:
Receiver side:
Receiver tools:
Lab el GN D RX Description The ground of transmitter. Receiver connected to encoder
VCC The power supply of the transmitter. ANT The hole to solder and connect antenna. (Please select the correct antenna length, which is 24cms.)
Features:
Low power consumption. Easy for application. On-Chip VCO with integrated PLL using crystal oscillator reference. Integrated IF and data filters. Operation temperature range: -100C ~ +600C. Operation voltage: 5 Volts. Available frequency at: 315/434 MHz
Decoder RX HT 648L:
Operating voltage: 2.4V~12V. Low power & high noise immunity CMOS
Technology. 8~18 address pins. 0~8 data pins. Built-in oscillator needs only a 5% resistor. Valid transmission indictor. Easily interface with an RF transmission medium.
Minimal external components.
RECEIVER ANALYSIS
The receiver part is more complex then transmitter for designing the receiver we make use of microcontroller (AT89S52) IC, decoder (HT 648) IC, ULN 2803A & LCD display (16X2) and other passive devices. Initially, the radio signal from the transmitter is received by the antenna receiver data output is fed to the decoder, where it is decoded. The output of this decoder is fed to the microcontroller (AT89S52) IC. Here we use 5 LSB pins of I/O port 0 to interface it with decoder, while all the 8pins of I/O port 2 are used to drive the relays. To display the message on the LCD (16X2) we use the all the pins of I/O port 1 and other pins of port 3 (P3.2, P3.3, P3.4) .
Decoder:
Here, we use 318 decoders as a series of CMOS LSIs. The 3 18 series of decoders receives serial address and data from that series of encoders that are transmitted by a carrier using an RF transmission medium. It then compares the serial input data twice continuously with its local address. If no errors or unmatched codes are encountered, the input data codes are decoded and then transferred to the output pins. The VT pin also goes high to indicate a valid transmission. In addition, the 318 decoders provide various combinations of address/data number in different packages.
Operation:
The 318 series of decoders provides various combinations of address and data pins in different packages. It is paired with the 3 18 series of encoders. The decoders receive data transmitted by the encoders and interpret the first N bits of the code period as address and the last 18N bits as data (where N is the address code number). A signal on the DIN pin then activates the oscillator which in turns decodes the incoming address and
data. The decoders will check the received address twice continuously. If all the received address codes match the contents of the decoders local address, the 18N bits of data are decoded to activate the output pins, and the VT pin is set high to indicate a valid transmission. That will last until the address code is incorrect or no signal has been received. The output of the VT pin is high only when the transmission is valid , otherwise it is low always.
Flow Chart:
Note: The oscillator standby is state disabled in the and activated as long as a logic high signal is applied DIN kept there to the be if no DIN pin. i.e., the should low is
signal input.
Decoder Timing:
LCD INTERFACE DETAILS INTERFACE PIN CONNECTIONS

Pin NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Symbol VSS VDD VO RS R/W E DB0 DB1 DB2 DB3 DB4 DB5 DB6 DB7 A K Level 0V 5.0V --H/L H/L H, H L H/L H/L H/L H/L H/L H/L H/L H/L ----Description Ground Supply voltage for logic Input voltage for LCD H : Data, L : Instruction code H : Read mode, L : Write mode Chip enable signal Data bit 0 Data bit 1 Data bit 2 Data bit 3 Data bit 4 Data bit 5 Data bit 6 Data bit 7 Backlight anode Backlight cathode
CONNECTION DETAILS:
In our applications we generally use the LCD only as a display (output) device even though we have an option of both write on and read from the LCD module. So we usually connect the R/W pin to Ground and use just to write and display what we want. Here we generally use 16 x 2 matrix LCD. There are 2 registers inside the LCD, Command Register and DATA register. The RS pin is used to select these registers. To select command register make RS = 0 and 1 to select DATA register. Command register is used to tell the LCD to start the display from a certain location, to clear or to perform any other operation. When we want to display a character or any number we should select the DATA register a write into it to display.
STEPS: For sending Command to the LCD

Write the command code on the DATA lines of the LCD Make the RS pin LOW to select Command Register Send a High-to-low pulse to the Enable pin to enable the selection the Command register Give little delay and repeat the process to send the next command to the LCD.
For displaying a data on LCD:

Write the data to be displayed on the DATA lines of the LCD Make the RS pin HIGH to select DATA Register Send a High-to-low pulse to the Enable pin to enable the selection of the DATA register
Give little delay and repeat the process to Display the next data.
Relays:
A relay is a simple electromechanical switch made up of an electromagnet and a set of contacts relays are found hidden in all sorts of devices. In fact, some of the first computer ever built used relays to implement Boolean gates.
Relay Construction:
Relays are amazingly simple device. There are four parts in every relay: Electromagnetic. Armature that can be attracted by the electromagnet. Spring. Set of electrical contacts.
The following figure shows these four parts in action
In this figure, we can see that a relay consists of two separate and completely independent circuits. The first is at the bottom and drives the electromagnet. In this circuit, a switch is a controlling power to the armature (BLUE). The armature is acting as a switch in the second circuit and light is on. When the electromagnet is not energized, the spring pulls the armature away and the circuit is not complete. In that case, the light is dark. Relays can be used to implement Boolean logic. When we purchase relays, we generally have control over several variables: The voltage and current that is needed to activate the armature. The voltage and current that can run through the armature and the armature contacts. The number of armatures (generally one or two). The number of contacts for the armature (generally one or two the relay shown here has two, one of which is unused). Whether the contact (if only one contact is provided) is normally open (NO) or normally closed (NC).
Relays Applications:
In general, the point of a relay is to use small amount of power in the electromagnet coming, say, from a dash board switch or a low power electronic circuit to move an armature that is able to switch a much larger amount of power. For example, we might want the electromagnet to energize using 5 volts and 50mili amps (250miliwatts), while the armature can support 120 volts AC at 2 Amps (240 Watts). Relays are quite common in home appliances where there is an electronic control tuning on something like a motor or a light. These are also common in cars, where the 12v supply voltage means that just about everything needs a large amount current. In later model cars, manufactures have started combining relay panels in to the fuse box to make maintenance easier. In place where a large amount of power needs to be switched, relays are often cascaded. In this case a small relay switches the power needed to drive a much larger relay, and that second relay switches the power to drive the load.
Power Supply MC78XX/LM78XX/MC78XXA 3-Terminal 1A Positive Voltage Regulator
Features:
Output Current up to 1A. Output Voltages of 5, 6, 8, 9, 10, 12, 15, 18, 24V.
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Thermal Overload Protection. Short Circuit Protection. Output Transistor Safe Operating Area Protection
Description:
The MC78XX/LM78XX/MC78XXA series of three terminal positive regulators are available in the TO-220/D-PAK package and with several fixed output voltages, making them useful in a wide range of applications. Each type employs internal current limiting, thermal shut down and safe operating area protection, making it essentially indestructible. If adequate heat sinking is provided, they can deliver over 1A output current. Although designed primarily as fixed voltage regulators, these devices can be used with external components to obtain adjustable voltages and currents.
ELECTRICAL CHARACTERISTICS (MC 7805/LM 7805):
MICROCONTROLLER (ATMEL AT89S52): FEATURES

8K Bytes of In-System Programmable (ISP) Flash Memory. 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
ATMEL Description
The AT89S52 is a low-power, high-performance CMOS 8-bit microcontroller with 8 Kbytes of in-system programmable Flash memory. The device is manufactured using Atmels high-density nonvolatile memory technology and is compatible with the industry-standard 80C51 instruction set and pin out. The on-chip Flash allows the program memory to be reprogrammed insystem 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 AT89S52 is a powerful microcontroller which provides a highly-flexible and cost-effective solution to many embedded control applications. The AT89S52 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 AT89S52 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.
CHAPTER -5 Radio frequency:

Radio frequency (RF) is a frequency or rate of oscillation within the range of about 3 Hz to 300 GHz. This range corresponds to frequency of alternating electrical signals used to produce and detect radio waves. Since most of this range is beyond the vibration rate that most mechanical systems can respond to, RF usually refers to oscillations in electrical circuits.
Special properties of RF electrical signals:

Electrical currents that oscillate at RF have special properties not shared by direct current signals. One such property is the ease with which they can ionize air to create a conductive path through air. This property is exploited by 'high frequency' units used in electric arc welding, although strictly speaking these machines do not typically employ frequencies within the HF band. Another special property is an
electromagnetic force that drives the RF current to the surface of conductors, known as the skin effect. Another property is the ability to appear to flow through paths that contain insulating material, like
the dielectric insulator of a capacitor. The degree of effect of these properties depends on the frequency of the signals.
Frequencies:
Name Symbo Frequency Industrial Applications Waveleng remote bridge crane & hoist control system l th Extreme ly low frequen cy Super low frequen cy Ultra low frequen cy Very low frequen cy Low frequen cy Medium frequen cy High frequen cy Very high frequen cy Directly audible when converted to sound (above ~20 Hz), communication with submarines
ELF
330 Hz
10100 M m
SLF
30300 Hz
110 Mm
Directly audible when converted to sound, AC power grids (5060 Hz)
ULF
3003000 H 1001000 z km
Directly audible when converted to sound, communication with mines
VLF
330 kHz
10100 k m
Directly audible when converted to sound (below ~20 kHz; or ultrasound otherwise)
LF
30300 kHz 110 km
AM broadcasting, navigational beacons, amateur radio Navigational beacons, AM broadcasting, amateur radio, maritime and aviation communication Shortwave, amateur radio, citizens' band radio, skywave propagation
MF
3003000 k 1001000 Hz m
HF
330 MHz
10100 m
VHF
30300 MHz
110 m
FM broadcasting, amateur radio, broadcast television, aviation, GPR, MRI
Ultra high UHF frequen Dept. of I.T. & E cy Super high
Broadcast television, amateur 3003000 M 10100 c radio, mobile telephones, telephones, Hz m wireless, remote keyless entry for automobiles, microwave ovens, GPR Page 31 Wireless networking, satellite 110 cm links, amateur radio, microwave links,
SHF
330 GHz
ISM (Industrial, Scientific and Medical) Bands:

The industrial, scientific and medical (ISM) radio bands were originally reserved internationally for the use of RF electromagnetic fields for industrial, scientific and medical purposes other than communications. In general, communications equipment must accept any interference generated by ISM equipment. Communication devices using the ISM bands must tolerate any interference from ISM equipment; these bands are typically given over to uses intended for unlicensed operation, since unlicensed operation typically needs to be tolerant of interference from other devices anyway. For many people, the most commonly encountered ISM device is the home microwave oven operating at 2.45 GHz. However, in recent years these bands have also been shared with license-free error-tolerant communications applications such as wireless LANs and cordless phones in the 915 MHz, 2450 MHz, and 5800 MHz bands. Because unlicensed devices already are required to be tolerant of ISM emissions in these bands, unlicensed low power uses are generally able to operate in these bands without causing problems for ISM users.The ISM band is also widely used for Radio-frequency identification (RFID) applications with the most commonly used band being the 13.56 MHz band. Several brands of radio control equipment use the 2.4 GHz band range for low power remote control of toys, from gas powered cars to miniature aircraft. Worldwide Digital Cordless Telecommunications or WDCT is an ISM band technology that uses the 2.4GHz radio spectrum. In our project module we used ISM band frequency 433/315MHz.
CHAPTER-6 SOURCE CODE:

ORG 0000H; MOV P2,#0; initial turn off relay CALL LCD_INI; MAIN: MOV A,#01H; ACALL COMMAND; CALL DELAY; CALL NAM1; MOV A,#0C0H; ACALL COMMAND; CALL DELAY; CALL NAM2; MOV P0,#0FFH; JNB VT,$; CALL DELAY; JB P0.0,FORWARD MOTORING; JB P0.1,REVERSE MOTORING; JB P0.2,UP MOTORING; JB P0.3,DOWN MOTORING;
CLRSCR; JMP MAIN; FORWARD MOTORING:SETB P2.0; CALL DISP1; CLR P2.O; CALL DELAY; JMP MAIN; REVERSE MOTORING: SETB P2.1; SETB P2.1; CALL LCD2; CLR P2.1; CALL DELAY; JMP MAIN UP MOTORING: SETB P2.2; SETB P2.2; CALL LCD3; CLR P2.2; CALL DELAY; JMP MAIN; DOWN MOTORING: SETB P2.3; SETB P2.3;
CALL LCD4; CALL DELAY CLR P2.3; CALL DELAY; JMP MAIN; DISP 1: MOV A,#80H; ACALL COMMAND; ACALL LCD1; RET; LCD_INI :MOV A,#38H; ACALL COMMAND; MOV A,#0EH; ACALL COMMAND; MOV A,#01H; ACALL COMMAND; MOV A,#06H; ACALL COMMAND; MOV A,#80H; ACALL COMMAND; RET; NAM1: MOV R1,#16;
MOV DPTR,#NAME1; UP0: CLR A; MOVC A,@A+DPTR; CALL DISP; INC DPTR; DJNZ R1,UP0; RET NAM2: MOV R1,#16; MOV DPTR,#NAME2; UP01: CLR A; MOVC A,@A+DPTR; CALL DISP; INC DPTR; DJNZ R1,UP01; RET LCD1: MOV A,#01H; ACALL COMMAND; MOV R1,#16; MOV DPTR,#MSG1; UP: CLR A; MOVC A,@A+DPTR;
CALL DISP; INC DPTR; DJNZ R1,UP; RET LCD2: MOV A,#01H; ACALL COMMAND; MOV R1,#16; MOV DPTR,#MSG2; UP1: CLR A ; MOVC A,@A+DPTR; CALL DISP; INC DPTR; DJNZ R1,UP1; RET LCD3: MOV A,#01H; ACALL COMMAND; MOV R1,#16; MOV DPTR,#MSG3 UP2: CLR A; MOVC A,@A+DPTR; CALL DISP;
INC DPTR; DJNZ R1,UP2; RET LCD4: MOV A,#01H; ACALL COMMAND; MOV R1,#16; MOV DPTR,#MSG4; UP3: CLR A; MOVC A,@A+DPTR; CALL DISP; INC DPTR; DJNZ R1,UP3; RET COMMAND: ACALL READY; MOV P1,A; CLR P3.5; CLR P2.6; SETB P3.4; CLR P3.4; CALL DELAY RET
DISP: ACALL READY; MOV P1,A; SETB P3.5; CLR P2.6; SETB P3.4; CLR P3.4; RET READY: CALL DELAY; RET DELAY: MOV 70H,#250; MOV 71H,#255; DJNZ 71H,$ ; RET CLRSCR: MOV A,#01H; ACALL COMMAND; RET NAME2: db"CONTROL PANEL" NAME1: db"CRANE & HOIST " MSG1: db" MOVING RIGHT MSG2: db" MOVING LEFT" MSG3: db" MOVING UP"
MSG4: db" MOVING DOWN "; END;
CHAPTER-7 Hardware Details:

The ICs and other important components used in this project work procured from CRANES SOFTWARE LIMITED BANGALURU. The details or the data sheets of the ICs are downloaded from internet the following are the websites that can be browsed for collecting the data sheets. 1. www.sunrom.com 2. www.holtek.com.tw 3. www.maxim-ic.com 4. www.alldatasheet.com 5. www.datasheets4u.com 6. www.fairchildsemi.com
The following are the ICs and other important components used in this project work. 1. AT89S52 microcontroller IC. 2. ULN 2809A.IC. 3. Encoder TX-HT640. 4. Decoder RX-HT648L. 5. RF Transmitter & Receiver. 6. Voltage Regulator. 7. Relays.
CHAPTER-8 Applications:
This mainly industrial-related area is where best known for its technological excellence leading to many exciting applications where productivity, safety and economy all have been improved. Following are some applications.
1. PINPOINT PRECISION THROUGH STEPLESS CONTROL ACHIEVED BY HEAVY EQUIPMENT MANUFACTURER

The benefits of radio remote control are evident not just in terms of speed and accuracy but also in terms of load-handling accuracy. One major manufacturer of heavy construction equipment recently took advantage of this feature by adapting two of its cranes to stepless control, then upgrading the radio remote to the 10k series. The controls on the two 80-foot-span cranes make it possible to swiftly and safely maneuver large engine assemblies into and out of tightly confined noise suppressing test cells. Operators find the transmitter to be comfortable, familiar and compatible with their earlier radio remote systems. Thanks to the dynamic braking afforded by the stepless motor controls, they also report fewer maintenance problems. Enclosed in a lightweight aluminum case with concealed antenna, the transmitter may be powered by either disposable battery packs or rechargeable cells.
2. TIME
MULTIPLE
SHARED
TECHNOLOGY
HELPS
CONTROL OVER 100 CRANES AT AIRCRAFT PLANT
At a major aircraft manufacturers plant, over 100 cranes operate on radio control without cross-interference, thanks to Time Multiple Shared (TMS) technology. The result is increased throughput and flexibility in production, painting, curing and transfer of parts to the kitting building. Three or four collocated remote radio control systems time share a single radio frequency channel. This means that in a single facility, the company can operate more than 100 control receivers with fewer than 50 transmitters on only 11 radio frequencies. The heart of the system is software based on both "random" and "demand" time division multiplexing techniques. Security of the system rests in the use of unique crane bridge and hoist code plugs for initiating transmitter control. First-come, first-serve protocol prevents two or more transmitters with identical code plugs from controlling the master receiver.
3. ANTI-COLLISION SYSTEMS WILL PREVENT MISHAPS WITH OTHER PLANT MACHINERY

When a machine tool manufacturer learned that a collision in another companys plant between an overhead crane and a piece of equipment had caused $300,000 of damage, it determined to take precautionary action. Thanks to the installation of an anti-collision system, the plant avoided the threat effectively and economically. The obstruction in the plant was a machining mill column. In its upward position it extends directly into the travel path of two 77 foot-span overhead cranes. By equipping the machining mill with a lowfrequency transmitter, it can signal its presence to the cranes. For their part, the cranes slow down and stop before impact but can move off in the reverse direction at full speed.
More conventionally, Laser Anti-Collision devices by Berlet are used for preventing cranes from colliding with each other. Cranes themselves can be operated with any one of the Berlet K series radio control devices independent of the anti-collision system.
4. RADIO CONTROL IS KEY TO EFFICIENCY IN BLANKING, STAMPING OPERATIONS

Radio control as opposed to conventional cab or pendant control is essential to the efficient and highly productive operations of blanking and stamping areas in plants, especially automotive plants. Todays plants all run on a justin-time system so cranes must become an integral part of the process. In stamping, for example, quality control and subsequent positioning may be performed by an operator as he/she handles the coil in the course of running the crane by radio. Thats where the flexibility of Berlet radio control helps the operator perform several functions sequentially and even simultaneously. At one Chrysler automotive plant, series 10-K remote radio-control systems direct cranes in the performance of material handling, tooling changes and maintenance procedures that relate to die sets and bolsters. A typical die change takes less than 10 minutes, thanks to the cranes. Radio control gives the operator the flexibility to quickly place the die sets and to service the bolster (which holds the dies) on either side of the transfer press. It would have been virtually impossible to service both sides with pendant control. The die maintenance crane is also used on a continual basis, under radio remote control. It handles dies in the wash area, opening and turning them
90 degrees while they are steam cleaned. The heaviest dies weigh around 15 tons.
5. CONTROLLED RANGE PLUS AT AUTO PLANT DETECTS, IGNORES EXTRANEOUS SIGNALS

An automotive stamping plant demands constant worker attention to safety procedures. It runs round the clock and requires continuous movement of large heavy metal dies into and out of high-speed presses where fenders, door panels, hoods, bumpers and many other parts are formed and stamped. At one Ford plant overhead cranes are used exclusively to perform these tasks, all under radio remote control. Many of them have double hoists with lift capacities to 50 tons. To maintain an excellent safety record, the plant has also installed Controlled Range Plus. This circle of safety automatically prevents the operator from controlling the crane beyond a pre-determined safe distance from the load. A problem, however, was that powerful harmonics from an electronic discharge machine (EDM) had the potential to cause interference. The threat was solved by the use of the Controlled Range Plus auto bypass option. It recognizes the harmonics and automatically permits normal crane operation regardless.
6. EXPERIMENT WITH RADIO REMOTE CONTROL MAKES THIS PAPER MAKER A TRUE BELIEVER.
One paper maker retrofitted two overhead bridge cranes with Series 8K radio remote controls as an experiment. A few years later it installed the technology on eight new cranes in a major expansion project involving two plants.
The eight cranes consist of three 50-ton process cranes on runways up to 480 feet long and 92 feet wide, and five maintenance cranes for maneuvering equipment during shutdowns. Radio control allows the operator to get the best line of sight possible for both kinds of operations. It is particularly important at a rewind station (where big rolls are rewound into smaller rolls) because loads are then transported to several different pieces of equipment located at different levels, including a mezzanine. The papermaker says that now it is familiar with radio-control operation, it will install the technology on all new cranes.
7. RADIO REMOTE CONTROL A NATURAL CHOICE FOR STEEL SERVICE CENTERS

When you see operators clambering over piles of steel trying to manipulate both loads and a heavy crane pendant, you know there must be an easier way! The easier way is with Berlet radio remote control, especially a system such as the 10-K with its lightweight transmitter that may even be carried around on a belt or in its own belly pack. At one large industrial service center where they move tons and tons of plate, bar, coil, pipes and more, the 10-K system makes light of overhead handling by many of the more than 70 overhead cranes. The transmitter weighs under two pounds and the crane-mounted receiver itself is just 18" by 18" by 7". Despite its small size, the transmitter is extremely rugged and easily withstands constant use and being dropped a couple 0f times a day. The 10-K system can be set up in as little as 3 hours. It can be quickly programmed in the field for most hoist control speeds simply by flipping a dip switch in the transmitter. The steel service center also makes use of the Time Multiple Sharing system to control up to four cranes on a single frequency.
8. STRUCTURAL STEEL COMPANY MAKES BIG BOOST IN HANDLING EFFICIENCY

A structural steel company reports a 40% increase in shop productivity by switching from wired pendant control of a 5-ton under hung crane to radio remote control. The radio replaces a bulky pendant and cord with a lightweight, hand-held transmitter. The plant uses a dog (beam clamp) to pick up beams up to 60 feet long, a job which used to take two persons to balance the beams on pendant. Now, one person can do the job more efficiently. Other times, on pendant, when the crane was operated by a single operator, there were times when he had to walk all the way round the 60-foot beam to facilitate placement of the load. Also, the operator used to be confined to a position near the load: now that person has the freedom to operate the crane from the best and safest position.
9. MINING
EQUIPMENT
MANUFACTURER
USES
RADIO
REMOTE THROUGHOUT
A major manufacturer of mineral processing equipment for international mining sites now uses radio remote control for every crane in its 200,000-square foot facility, from raw materials handling to truck loading for shipment to the customer. The manufacturer has progressed from the Berlet Series 8-K to the Series 10K with Time Multiple Sharing (TMS). This technology permits control of up to 4 cranes on a single frequency, and allows many different ones to operate in close quarters without crossinterface
Manufacturing begins with punching, cutting, drilling and welding. During each step radio remote control is used for the precise movement of parts. There are no crane operators as such: everyone is a crane operator. Whenever workers need a crane movement, they get the hand-held control and do it themselves its that simple. The technology has made a big impact in the machine shop too. Large pieces of plate and bar steel must be positioned onto lathes and machining centers. Radio control accomplishes this more efficiently and safely because operators dont have to worry about where the pendant wire is located when loading a machine. They also have more control over the part. Plant management is very satisfied with the reliability and durability of the technology, including the hand-held controllers, which have stood up to heavy-duty use even better than expected. Laser anti-collision technology is also under consideration for the plant.
10.
ANTI-COLLISION DEVICES WORK FOR STACKER
CRANES AS WELL
Some automated storage systems call for more than one stacker crane to operate in an aisle, which demands foolproof anti-collision methods. Berlet makes this possible through the application of 14-K Laser AntiCollision technology. One food manufacturer uses the technology to ensure manned stacker cranes dont collide in 420 foot-long aisles where they travel at speeds to 525 fpm. The transmitter on each crane sends a signal to any other in the same aisle. Three separate output relays are wired to override the onboard directional and speed controls, one for each predetermined set distance.
At the furthest distance (100 feet) the Anti-Collision technology sounds a warning alarm. At the middle distance, the technology automatically slows the crane down. At the nearest distance (10 feet), it brings the crane to a halt, using the cranes installed electric brakes. The technology can be installed on any number of cranes without cross-interference and includes built-in monitoring and an alarm in case of internal failure. It requires minimal maintenance.
11.
OUTBOARD MOTOR PLANT FINDS SUCCESS IN
HOISTING PROCESS
A plant that finishes outboard motor engine castings and fits them with components now use 10-K series for overhead hoists in the process. One of the functions at the plant is to treat the castings via an 11-stage conversion and coating process, where an Allen Bradley PLC (programmable logic controller) controls a 700 foot-long closed-loop monorail. The monorail is equipped with 10 Electro Lift Hoists mounted on a track 12 feet above the plant floor. They were originally fitted with pendant controls to facilitate overriding of the PLC for loading, unloading or bypassing one of the conversion stages. It was an awkward operation that included the need to hook the pendant down with an 8-foot metal rod. Now, all 10 of the hoists are controlled by a single Series 10-K transmitter. By using the 10-Ks thumb-wheel switches, an operator can dial up any individual hoist. Once a hoist is selected, the operator removes it from PLC control via a manual toggle switch, then lowers or raises it with the down or up toggle
switch. The hoist is then returned to PLC control. Up to 1000 hoists could be controlled this way using Berlet technology.
12.
LABOR EFFICIENCY GETS BIG BOOST AT PAPER
MANUFACTURERS PLANT
When the rolls on a paper-making machine needed to be lifted several times a day for repairs, this manufacturer relied on a 35-ton overhead cabcontrolled crane, with one operator aloft and two on the ground giving directions. Conditions at the plant are not pleasant 40 feet up because steam from the paper drying process raises the temperature there up to 43C (110F). The company decided to switch to a radio remote control system to utilize man power better and improve working conditions. A number of safety features are incorporated in the system. A warning alarm on the crane can be activated if necessary to warn workers of crane motion. Crane power can be tuned on only after six conditions are met by the radios microcomputer that safe reliable communications have been established. The radio remote system reduces crewing requirements from three to two persons per crane, and uncomfortable crane cab conditions leading to lost work time are a thing of the past. Installation of the entire system took less than two days.
CHAPTER-9 References:
The following are the references made during the development of this project work. 1. Geial.E.Williams,practical transistor circuit design and analysis, Tata Mc Graw Hill, 1996, ISBN 0-07-099672-5. 2. K.R Brothker,Integrated Circuits, Khannan Publications, 1996. Manuals: 1. Advanced CMOS Logic Data Book, Texas Instruments. 2. Modern IC Data & Substitution manual, 1998 ISBN 81-7029-943-8. Following are the sites that have been browsed for collecting literature 1. www.atmel.com 2. www.wikipedia.org 3. www.howstuffswork.com 4. www.electronicsforu.com 5. www.texasinstruments.com 6. www.nseelectronics.com

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Industrial remote bridge crane & hoist control system

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Industrial remote bridge crane & hoist control system

The Remote Controller

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CHAPTER-3 BLOCK DIAGRAM:

Hand Held Device Device Controller 4 channel Relay

Hand Held Device:

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Block Diagram (Hand held Remote Control):

SWITCH 2 ENCODER SWITCH 3

9 Volt Battery SWITCH 4

Industrial remote bridge crane & hoist control system

approximately 400-foot (open area) outdoors.

Indoors, the range is

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DC DC Motor2 Motor2 Page 9

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Industrial remote bridge crane & hoist control system

CHAPTER -4 CIRCUIT DIAGRAM & ANALYSIS:

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Transmitter Tools: RF_TX_315MHz:

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Easy interface with an RF or infrared transmission media. Minimal external components

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Address/Data programming (Preset):

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Minimal external components.

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Industrial remote bridge crane & hoist control system

LCD INTERFACE DETAILS INTERFACE PIN CONNECTIONS

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Industrial remote bridge crane & hoist control system

STEPS: For sending Command to the LCD

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For displaying a data on LCD:

The following figure shows these four parts in action

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Industrial remote bridge crane & hoist control system