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Sunday, March 17, 2013


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 :-      




        





 Applications :-

·        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 :-




             The IR transmitter circuit is built around the timer IC 555. It is in the As table mode with the timing components R1, R2, VR and C1. The oscillations available at the output are close to 38 kHz and the IR LEDs emit Pulsed IR rays in this frequency. Since the IR Ray is invisible, a Red LED is provided to confirm the working of the circuit. This LED blinks in when IR LED emits IR rays. Adjust VR to get exact frequency for the IR receiver


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 :-

·        www.google.co.in
·        www.talkingelectronics.com
·        www.datasheetcatalog.com
.     www.jvsivaprasadelectronics.blogspot.in











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