REMOTE CONTROL BASED HOME APPLIANCES
CONTENTS
:-
1.
Introduction
2.
Product
Description
3.
Functional
Block Diagram
4.
Circuit
Description
5.
List
of Components
a) 230v/12v, 500mA Transformer
b) IC CD 4017BC
c) ThreeTerminal Positive Voltage Regulator IC 7805
d) TSOP 1738 IR Sensor
e) Relay
f) Resistors
g) Transistors
h) IN4007 Diode Rectifiers
i) Capacitors
j) Transmitter
6. GCB Layout and Fabrication
7. Soldering
8.
Testing
9. Applications
10. Conclusion
11. Project References
Introduction :-
Remote control for home
appliances is an absolute necessity in our fast-paced life. As a result, much
important has been given to this aspect and a range of remote controls are
prevalent today. One of the most common is that which makes use of IR
radiations at particular frequencies.
Our product is a Remote
Operated Home Appliance or Remote controlled Home appliance. The circuit is
connected to any of the home appliances (lamp, fan, radio, etc) to make the
appliance turn on/off from a TV, VCD, and VCR, Air Conditioner or DVD remote
control. The circuit can be activated from up to 10 meters. It is very easy to
build and can be assembled on a general-purpose GCB.
The circuit essentially
consists of the receiver an IR module, CD4017 IC, Transistors, diodes, IC 1738,
Capacitors, relay
and other components.
Production Description
:-
Model
Description :-
Connect this circuit to any of your home appliances (lamp, fan,
radio, etc) to make the appliance turn on/off from a TV, VCD or DVD remote
control. The circuit can be activated from up to 10 meters. The 38 kHz infrared
(IR) rays generated by the remote control are received by IR receiver module
TSOP1738 of the circuit. Pin 1 of TSOP1738 is connected to ground, pin 2 is
connected to the power supply through resistor R5 and the output is taken from
pin 3. The output signal is amplified by transistor T1 (BC558). The amplified
signal is fed to clock pin 14 of decade counter IC CD4017 (IC1). Pin 8 of IC1
is grounded, pin 16 is connected to Vcc and pin 3 is connected to LED1 (red),
which glows to indicate that the appliance is ‘off.’
Functional
Block Diagram :-
Parts List
The following parts
will be required for making the above explained infra red remote
control circuit:
Resisitors : R1, R3 = 100 ohms, R2 = 100K,
R4 = 4K7, R5 = 10K,
Capacitors :
C1, C2, C4= 22uF/25V, C6 = 4.7uF/25V, C3 = 0.1,
CERAMIC, C5 =1000uF/25V,
Transistors : T1 = BC557B, T2 = BC547B,
ALL DIODES ARE =
1N4007,
IR SENSOR = TSOP1738
image: Vishay
IC1 = CD4017BC,
IC2 = 7805,
Transformer = 230V/12V 500mA
Relay = 5V 230V
Circuit
Description :-
Referring to the figure, we see that the entire layout consists
of just a couple of stages viz: the IR sensor stage and the flip-flop stage.
Thanks to the highly versatile, miniature IR sensor unit which
forms the heart of the circuit and directly coverts the received IR waves from
the transmitter unit into the relevant logic pulses for feeding the flip flop
stage.
The sensor basically consists of just three leads viz: the
input, the output and the biasing voltage input lead. The involvement of only
three leads makes the unit very easy to configure into a practical
circuit. The sensor is specified for operating at 5 volts regulated voltage
which makes the inclusion of the 7805 IC stage important. The 5 voltage supply
also becomes useful for the flip flop IC 4017 and is appropriately supplied to
the relevant stage.
When a IR signal becomes incident over the sensor lens, the
inbuilt feature of the unit activates, triggering a sudden drop in its output
voltage. The PNP transistor T1 responds to the negative trigger pulse from the
sensor and quickly pulls the positive potential at its emitter to the collector
across the resistor R2. The potential developed across R2 provides a positive
logic high to the IC 4017 input pin #14. The IC instantly flips its output and
changes its polarity. The transistor T2 accepts the command and switches
the relay according to the relevant input provided to its base. The relay thus
switches the connected load across its contacts alternately in response to the
subsequent triggers received from the IR transmitter unit. For the sake of
convenience the user may use the existing TV remote control set unit as the
transmitter for operating the above explained control circuit. The referred
sensor is well compatible with all normal TV or DVD remote control handset and
thus can be appropriately switched through it.
The entire circuit is powered from an ordinary
transformer/bridge network and the entire circuit may be housed inside a small
plastic box with the relevant wires coming out of the box for the desired
connections.
List
of Components :-
A) 230V/12V
500 mA Transformer :-
General
Description :-
A transformer is a static electrical device that transfers energy by coupling between its winding circuits. A varying current in the primary winding creates a varying
magnetic in the transformer's core and thus a varying
magnetic flux through the secondary winding. This varying magnetic flux induces a varying electromotive force (emf) or voltage in the secondary winding.
The
transformer is based on two principles: first, that an electric current can
produce a magnetic field and second that a changing magnetic field within a coil of
wire induces a voltage across the ends of the coil (electromagnetic induction).
Changing the current in the primary coil changes the magnetic flux that is
developed. The changing magnetic flux induces a voltage in the secondary coil.
Induction Law :-
The voltage induced across the secondary coil may be
calculated from Faraday's law of induction, which states that:
where Vs is
the instantaneous voltage, Ns is the number of
turns in the secondary coil and Φ is the magnetic flux through one turn of the
coil. If the turns of the coil are oriented perpendicularly to the magnetic
field lines, the flux is the product of the magnetic flux
density B and
the area through which it
cuts. The area is constant, being equal to the cross-sectional area of the
transformer core, whereas the magnetic field varies with time according to the
excitation of the primary. Since the same magnetic flux passes through both the
primary and secondary coils in a quasi ideal transformer,[36] the instantaneous voltage across the primary winding
equals
Taking
the ratio of these two equations, gives the basic equation,
where Np/Ns is
the turn ratio, usually
expressed in round numbers, the value of this ratio being respectively higher and
lower than unity for step-down and step-up transformers.
If a load is connected to the
secondary winding, current will flow in this winding, and electrical energy
will be transferred from the primary circuit through the transformer to the
load. Transformers may be used for AC-to-AC conversion frequencies ranging from
power to audio or radio frequencies and higher.
By appropriate selection of the
ratio of turns, a transformer thus enables an AC voltage to be stepped-up by
making Ns greater than Np,
or stepped-down by making Ns less than Np.
Transformer winding coils are usually wound around ferromagnetic cores but can also bear wound.
Transformer universal emf equation :-
If the
flux in the core is purely sinusoidal, the relationship for either winding
between its rms voltage Erms of the winding, and the supply
frequency f, number of
turns N, core
cross-sectional area a in m2 and peak magnetic flux density Bpeakin Wb/m2 or T (tesla) is given by the universal
emf equation:
If the flux does not contain even harmonics the following equation can be used for half-cycle average voltage Eavg of any waveshape:
Schematic Diagram :-
Specifications :-
· voltage:
2 x 12V
· current:
1 x 500mA
· rated
power: 12VA
A) CD
1047BC IC:-
GENERAL DESCRIPTION :-
The CD4017BC is
a 5-stage divide-by-10 Johnson counter with 10 decoded outputs and carry out
bit.
These counters are cleared to their zero count by a logical “1” on their
reset line. These counters are advanced on the positive edge of the clock
signal when the clock enable signal is in the logical “0”state.
The configuration of the CD4017BC permits medium speed operation and
assures a hazard free counting sequence. The 10/8 decoded outputs are normally
in the logical “0” state and go to the logical “1” state only at their
respective time slot. Each decoded output remains high for 1 full clock cycle.
The carry-out signal completes a full cycle for every 10/8 clock input cycles
and is used as a ripple carry signal to any succeeding stages.
The CD 4017 is called a
COUNTER or DIVIDER or DECADE COUNTER. It is a very handy chip for producing
"Running LED effects" etc.
It has 10 outputs. For normal operation,
the clock enables and reset should be at ground.
Output "0" goes HIGH on the
rise of the first clock cycle.
On the rise of the second clock cycle,
output "0" goes LOW and output "1" goes HIGH. This process
continues across the ten outputs and cycles to output "0" on the
eleventh cycle.
The "Carry Out" pin goes LOW
when output "5" goes HIGH and goes HIGH when output "0"
goes HIGH. In other words, "Carry Out" is HIGH for outputs 0, 1, 2, 3
and 4. It is LOW when the following outputs are active: 5, 6, 7, 8and 9.
When RESET (pin 15) is taken HIGH, the
chip will make output "0" go HIGH and remain HIGH. When "Clock
Inhibit" (pin 13) is taken HIGH, the counter will FREEZE on the output
that is currently HIGH.
The clock signal must have a rise time faster than
5μsecs (VDD=15v).
APPLICATIONS
:-
·
Auto motive
·
Instrumentation
·
Medical Electronis
·
Alarm systems
·
Industrial electronics and Remote metering
SCHEMATIC
DIAGRAM :-
Absolute
Ratings :-
Symbol
|
parameter
|
value
|
unit
|
Vcc
|
Supply voltage
|
-0.5 to +7
|
V
|
Vi
|
DC input voltage
|
-0.5
to VCC + 0.5
|
V
|
Vo
|
DC output Voltage
|
-0.5 to VCC + 0.5
|
V
|
Iik
|
DC input diode current
|
±20
|
mA
|
Iok
|
Dc output diode current
|
±20
|
mA
|
Io
|
DC output current
|
±25
|
mA
|
Icc or IGND
|
DC Vcc or Ground Current
|
±50
|
mA
|
Tstd
|
Storage Temperature
|
-65 to +150
|
oc
|
A) Three-Terminal
Positive Voltage Regulator IC 7805 :-
General Description :-
The
Three terminal positive voltage regulator IC 7805 is complete voltage regulator
with outstanding ripple rejection and superior line load regulation. Current
limiting is included to limit peak output current to a safe level. Safe area
protection for the output transistor is provided. If internal power dissipation
is too high, thermal shutdown occurs. Although designed primarily as fixed
voltage regulators, these devices can be used with external components to
obtain adjustable voltages and currents.
Schematic Diagram :-
Features :-
• Maximum 1A
output
• Output voltage tolerance ±2%
• Load regulation 0.3%
• Thermal overload protection
• Short circuit current limit
• Output transistor safe area
protected
• Continuous dissipation 15W
Absolute
Ratings :-
symbol
|
Characteristics
|
Value
|
Unit
|
Vo
|
Output Voltage
|
4.75 to 5.25
|
V
|
∆Vv
|
Line Regulation
|
50 to 100
|
mV
|
∆Vi
|
Load Regulation
|
50 to 100
|
mV
|
∆Ib
|
Quiescent current
|
8.0
|
mA
|
A) TSOP
1738 IR Sensor :-
General Description :-
The TSOP1738
series are miniaturized receivers for infrared remote control systems. PIN
diode and preamplifier are assembled on lead frame, the epoxy package is
designed as IR filter. The demodulated output signal can directly be decoded by
a microprocessor. TSOP1738 is the standard IR remote control receiver series,
supporting all major transmission codes.
The TSOP1738 – series are miniaturized receivers for
infrared remote control systems. PIN diode and preamplifier are assembled on
lead frame, the epoxy-package is designed as IR filter. The demodulated output
signal can directly be decoded by a microprocessor. TSOP17XX is the
standard IR remote control receiver series, supporting all major transmission
codes.
The circuit of the TSOP1738 is designed
in that way that unexpected output pulses due to noise or disturbance signals
are avoided. A band pass filter, an integrator stage and an automatic gain
control are used to suppress such disturbances. The distinguishing mark between
data signal and Disturbance signal are carrier frequency, burst length and duty
cycle.
The data signal should fulfill the following
condition:
• Carrier frequency should be close to
center frequency of the band pass (e.g. 38 kHz).
• Burst length should be 10
cycles/burst or longer.
• After each burst which is between 10
cycles and 70 cycles a gap time of at least 14 cycles is necessary.
• For each burst which is longer than
1.8ms a corresponding gap time is necessary at some time in the data stream.
This gap time should have at least same length as the burst.
• Up to 1400 short bursts per second
can be received continuously.
Some
examples for suitable data format are:
NEC
Code, Toshiba Mecum Format, Sharp Code, RC5
Code,
RC6 Code, R–2000 Code, Sony Format (SIRCS). When a disturbance signal is
applied to the TSOP1738 it can still receive the data signal. However the
sensitivity is reduced to that level that no unexpected pulses will occur.
Some
examples for such disturbance signals which are suppressed by the TSOP1738 are:
•
DC light (e.g. from tungsten bulb or sunlight)
•
Continuous signal at 38 kHz or at any other frequency
•
Signals from fluorescent lamps with electronic ballast
Diagram :-
Features :-
·
Photo
detector and preamplifier in one package
·
Internal
filter for PCM frequency
·
Improved
shielding against electrical field disturbance
·
TTL
and CMOS compatibility
·
Output
active low
·
Low
power consumption
·
High
immunity against ambient light
·
Continuous
data transmission possible (up to 2400 bps)
·
Suitable burst length .10 cycles/burst
Absolute Ratings :-
Symbol
|
Parameters
|
Value
|
Unit
|
Vs
|
Supply Voltage
|
-0.3 to 6.0
|
V
|
Is
|
Supply Current
|
5.0
|
mA
|
Vo
|
Output Voltage
|
-0.3 to 6.0
|
V
|
Io
|
Output Current
|
5.0
|
mA
|
Ti
|
Junction Temperature
|
100
|
oC
|
Ptot
|
Power Consumption
|
50
|
MW
|
Tsd
|
Soldering Temperature
|
260
|
oC
|
A) Relay
:-
General Description :-
Relays are components which allow a low-power circuit to switch a
relatively high current on and off, or to control signals that must be
electrically isolated from the controlling circuit itself.
A relay is an electrically operated switch. Many relays use an electromagnet to operate a switching mechanism mechanically, but other
operating principles are also used. Relays are used where it is necessary to
control a circuit by a low-power signal (with complete electrical isolation
between control and controlled circuits), or where several circuits must be
controlled by one signal. The first relays were used in long distance telegraph
circuits, repeating the signal coming in from one circuit and re-transmitting
it to another.
Applications :-
Relays are used for:·
Amplifying
a digital signal, switching a large amount of power with a small operating
power. Some special cases are:
·
A
telegraph relay, repeating a weak signal received at the end of a long wire
·
Controlling
a high-voltage circuit with a low-voltage signal, as in some types of modems or audio amplifiers,
·
Controlling
a high-current circuit with a low-current
signal, as in the starter solenoid of an automobile,
·
Detecting
and isolating faults on transmission and distribution lines by opening and
closing circuit breakers (protection relays),
A DPDT AC coil relay with "ice cube" packaging·
Isolating
the controlling circuit from the controlled circuit when the two are at
different potentials, for example when controlling a mains-powered device from
a low-voltage switch. The latter is often applied to control office lighting as
the low voltage wires are easily installed in partitions, which may be often
moved as needs change. They may also be controlled by room occupancy detectors
to conserve energy,
·
Logic
functions.
·
Time
delay functions. Relays can be modified to delay opening or delay closing a set
of contacts. A very shorts (a fraction of a second) delay would use a copper
disk between the armature and moving blade assembly. Current flowing in the
disk maintains magnetic field for a short time, lengthening release time. For a
slightly longer (up to a minute) delay, a dashpot is used. A dashpot is a piston filled with fluid that
is allowed to escape slowly. The time period can be varied by increasing or
decreasing the flow rate. For longer time periods, a mechanical clockwork timer
is installed.
·
Vehicle
battery isolation. A 12v relay is often used to isolate any second battery in
cars, 4WDs, RVs and boats.
·
Switching
to a standby power supply.
Specifications :- ·
Coil Power: 360mW
·
Nominal Voltage: 5Vdc
·
Pick-Up Voltage: 3.8Vdc
·
Drop-Out Voltage: 0.5Vdc
·
Maximum Voltage: 6.5Vdc
·
Coil Resistance: 70ohm
·
Insulating Resistance : 100Ω
·
Ambient temperature : -40oc
to 75oc
Schematic
Diagram :-
A) Resistors
:-
General
Description :-
A
resistor will limit the current flow through itself to a calculable value based
upon its resistance and the applied voltage. This means a resistor can be used
to run a low voltage device from a higher voltage power supply by limiting the
required power to a predetermined level. Resistors are not polarity sensitive.
Tolerance : The Tolerance of a resistor
refers to how close its actual resistance has to be the value marked on it. Common
tolerance are 5% and 1%.
Wattage
: Depending
on the power required of a circuit, resistor wattage needs to be calculated to
ensure that they don’t over heat. The more common ratings available for
resistors are ¼ watt ½ watts, 1 watt & 5 watt. The wattage required for
different circuits can be calculated by using the formula described later.
Values
: Because
it would be impractical to carry every possible value of resistor, they are
available in pre-selected ranges. These ranges are known as preferred values.
The E 12 series, which is the most common series is denoted as : 10Ω, 12Ω, 15Ω,
18Ω, 22Ω, 27Ω, 33Ω, 39Ω, 47Ω, 56Ω, 68Ω, 82Ω.
This does not limit the range of resistors to a
total of twelve values, but each resistor value must begin with a number from
the series and be a multiple of x0.1, x1, x10, x100, x1000, x10000 etc. i.e
1.5Ω, 15Ω, 150Ω, 1500Ω, 15,000Ω.
The E24 series has 24 values per 100 which includes
the above sequence plus these extra values 11Ω, 13Ω, 16Ω, 20Ω, 24Ω, 30Ω, 36Ω,
43Ω, 51Ω, 62Ω, 75Ω, 91Ω.
Colour
Code Reading :-
Formula
Wheel :-
Using this formula
wheel it is possible to calculate power, volts, amps or resistance for a given
problem. i.e if you have two of the variables, for example power and volts, it
is possible to find the amps in a circuit.
A) Transistors:-
General Description :-
Bipolar
Transistors are current amplifying devices. When a small signal current is
applied at the input terminal (the base) of the bipolar transistor, an
amplified reproduction of this signal appears at the output terminals (the
collector).
Low frequency, general purpose small
signal transistors widely used in audio, switching and television circuits. The
BC547-9 series and BC557-9 series are functionally identical to the common
BC107-9 series. All have a maximum power dissipation of 500mW. They have
essentially similar specifications and can generally be substituted for one
another (within the PNP and NPN groups of three each). All devices are housed
in standard TO-92 plastic packages.
TRANSISTOR
BC547B (NPN) :
Schematic
Diagram :-
·
Well suitable
for TV and Home theater appliances equipment
·
Small load
switch transistors with high gain and low saturation voltage
Absolute
Ratings :-
Symbol
|
Parameters
|
Value
|
Unit
|
VCBO
|
Collector
–Base voltage ( Ie = 0)
|
50
|
V
|
VCEO
|
Collector-Emitter Voltage( Ib = 0)
|
45
|
V
|
VEBO
|
Emitter-Base Voltage (Ic=0)
|
6
|
V
|
IC
|
Collector
Current
|
100
|
mA
|
ICM
|
Collector
Peak Current
|
200
|
mA
|
Ptot
|
Total
Dissipation at Tc= 25oC
|
500
|
MW
|
Tstg
|
Storage
Temperature
|
-65 to 150
|
oC
|
Tj
|
Max.OperatingJunctionTemperature
|
150
|
oC
|
TRANSISTOR BC 557B (PNP)
Schematic
Diagram :-
Apllications
:-
·
Well Suitable for TV and Home Theater
appliances
·
Small load switch transistor with high
gain and low saturated voltage
Absolute
Ratings :-
Symbol
|
Parameters
|
Value
|
Units
|
VCBO
|
Collector-Base
Voltage (IE = 0)
|
-50
|
V
|
VCEO
|
Collector-Emitter
Voltage (IB = 0)
|
-45
|
V
|
VEBO
|
Emitter-Base
Voltage (IC = 0)
|
-5
|
V
|
IC
|
Collector
Current
|
-100
|
mA
|
ICM
|
Collector Peak
Current
|
-200
|
mA
|
Ptot
|
Total
Dissipation at TC = 25 oC
|
500
|
mW
|
TSTG
|
Storage
Temperature
|
-65 to 150
|
oC
|
Tj
|
Max. Operating
Junction Temp.
|
150
|
oC
|
A) IN
4007 Diode Rectifiers :-
General
Description :-
In electronics, a diode is a two-terminal electronic component with an asymmetric transfer
characteristics, with low (ideally zero) resistance to current flow in one direction, and high (ideally
infinite) resistance in the other
Schematic
Diagram :-
Specifications :-
·
Diffused Junction
·
High Current Capability and Low Forward
Voltage Drop
·
Surge Overload Rating to 30A Peak
·
Low Reverse Leakage Current
·
Plastic Material: UL Flammability
Classification Rating 94V-0
Absolute
Ratings :-
Symbol
|
Parameters
|
Value
|
Units
|
VRRM
|
Peak Repetitive Reverse Voltage
|
1000
|
V
|
VR(RMS)
|
RMS Reverse Voltage
|
700
|
V
|
Io
|
Average
Rectified Output Current
|
1.0
|
A
|
IFSM
|
Peak Forward Surge Current
|
30
|
A
|
IFM
|
Forward Voltage
|
1.0
|
V
|
IRM
|
Peak Reverse Current
|
5.0
|
µA
|
Tj and Tstg
|
Operating and Storage
Temperature
Range
|
-65 to 175
|
oC
|
RӨJA
|
Typical Thermal Resistance
Junction to Ambient
|
100
|
K/W
|
A)
Capacitors :-
General Description :-
A
capacitor works on the principle of having two conductive plates which are very
close and are parallel to each other. When a charge is applied to one plate of
the capacitor, the electrons will generate an approximately equal, but opposite
charge on the other plate. Capacitors will pass AC current, but will block DC
current. A capacitor can also be used to smooth voltage ripple, as in DC power
supplies. Capacitance is measured in Farads (F).
Capacitor
Parameters :-
Capacitors have five parameters:
·
Capacitance (Farads),
·
Tolerance (%),
·
Maximum Working Voltage (Volts)
·
Surge Voltage (Volts) and leakage
Because a Farad is a very large
unit, most capacitors are normally measured in the ranges of Pico, nano and
micro farads.
Working Voltage :-
This refers to
the maximum voltage that should be placed across the capacitor under normal
operating conditions.
Surge Voltage :-
The maximum instantaneous voltage
a capacitor can withstand. If the surge voltage is exceeded over too long a
period there is a very good chance that the capacitor will be destroyed by the
voltage punching through the insulating material inside the casing of the
capacitor. If a circuit has a surging characteristic, choose a capacitor with a
high rated surge voltage.
Leakage :-
Refers to the
amount of charge that is lost when the capacitor has a voltage across its
terminals. If a capacitor has a low leakage it means very little power is lost.
Generally leakage is very small and is not normally a consideration for general
purpose circuits.
Tolerance :-
As with
resistors, tolerance indicates how close the capacitor is to its noted value.
These are normally written on the larger capacitors and encoded on the small
ones.
Code
|
Tolerance
|
Code
|
Tolerance
|
C
|
±.25pF
|
J
|
±5%
|
E
|
±1pF
|
K
|
±10%
|
D
|
±0.5Pf
|
L
|
±15%
|
G
|
±2%
|
M
|
±20%
|
N
|
±30%
|
Z
|
+80-20%
|
Capacitor Markings :-
There are two methods for marking
capacitor values. One is to write the information numerically directly onto the
capacitor itself. The second is to use the EIA coding system.
EIA Coding :-
The EIA code works on a very similar principle
to the resistor colour code. The first two digits refer to the value with the
third being the multiplier. The fourth character represents the tolerance. When
the EIA code is used, the value will always be in Pico-Farads (see Decimal
Multipliers).
Example 103K
This expands to:
1 = 1, 0 = 0, 3 = x 1,000
K = 10% (sec Capacitor Tolerance for
listings)
Then we combine these numbers together:
1 0 x 1 000 = 10 000pF = 0.01μF, = 10n
±10% tolerance
Various Capacitors :-
A) Transmitter
:-
The Carrier
frequency of transmitter may be 36 kHz or 38
kHz. The Control codes are sent to the receiver of the device in Serial Format. This format is Modulated to the carrier frequency by the On / Off method. In the Remote, the IR signals are generated
using an IR LED which emits Modulated IR rays. This part explains
the details of IR
transmission protocol and the design of IR
Transmitter. . The data is transmitted at the
range of 100-2000
bps.
The transmitter which is using in this project generates 38
kHz modulated Square wave which are send to the IR
LED for transmission. The Carried
frequency is Amplitude modulated by the data usually with full on / off type modulation. The Oscillator circuit in the Remote control makes the IR LED to
turn on /off through the TTL voltage generated by the Key board decoding IC. At the Receiver end, the Photodiode of the IR sensor, receives the modulated signals and
activate the controlling circuit to perform the functions.
Circuit
Diagram :-
GCB
Layout and Fabrication :-
Fabrication Process :-
The materials
required for GCB
fabrication process are a main circuit board, electrical components using in
project, soldering machine, electric wires, etc.
Steps involving to make a GCB :
·
Preparing the layout of the track: The
track layout of the electronic circuit may be drawn on a white paper. The
layout should be made in such a way that paths are in each routes. This enables GCB to be more compact and economical
·
Transferring the layout to the board:
The layout made on the white paper should be redrawn on the board using paint
or nail varnish.
Soldering
the GCB :-
Tinning
the Soldering tip :-
Before use, the tip of the soldering gun must be
tinned. tinning is the process of coasting a soldering tip with a thin coat of solder. this aids in heat transfer between
the tip and the component whish are soldering, and also gives the solder a base
from which to flow from.
WARMUP
THE IRON:-
Warm up the soldering iron or gun thoroughly. this
is especially important if the iron is
new because it may have been packed with some kind of coasting to prevent
corrosion.
THOROUGHLY
COAT THE TIP IN SOLDER:-
Thoroughly coat the solder tip in solder. it is very
important to cover the entire tip. You’ll use a considerable amount of
soldering during this process and it'll drip, run the solder up and down the
tip and completely around it to totally cover it in molten solder
Now, place the soldering iron onto the contact to
melt the solder. When the solder in the contact melts, slide the wire into the
contact. Remove the iron and hold the contactor still while the solder
solidifies again. This should all take around 1-3 seconds.
CLEAN
THE SODERING TIP :-
After
certain that the tip is totally coated in solder, wipe the tip off on the wet
sponge to remove the entire flux residue. Do this immediately so there is no
time for the flux to dry out and solidify.
JOB
DONE:-
The soldering
job on GCB has done.
GCB
Layout :-
Testing
:-
Initial stage of the project,
assemble all components in bread board. Because assemble components in bread
board is easy and removable. If any problem occurs simply remove the component
from the board and have availability for replace the component from the board.
After completing the circuit on bread board test the circuit functioning.
Calculate the voltage at every step of the circuit. After testing, solder the circuit on PCB or GCB.
Applications
of the Project :-
·
Optimized for home appliances like
electrical bulbs, fans, motors, etc, with remote control.
·
Suitable for appliances which are in 15
meters distances.
·
Most useful for handicapped persons.
Project
References :-
·
Gouse Basha sir, Lecturer in GOVT.Polytechnic College,
DEPT. of D.EEE
·
Subbanna
sir, Lecturer in GOVT.Polytechnic College, Dept. of D.EEE
·
G.
Sudhakar Rao sir, HEEES & Lecturer in GOVT.Polytechnic College, Dept. of
D.EEE
·
Z.Ramesh
Babu sir, Principle of GOVT.Polytechnic College.
Reference
websites :-
download electronics complete book(most useful)