industrial automation using cell phone progress

8/12/2019 Industrial Automation Using Cell Phone Progress

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ON

USING

SUBMITTED BY: PROJECT TEAM:

GROUP No. : I-2 PROJECT GUIDE:

ELECTRONICS & INSTRUMENTATION Mr. SANTOSH DUBEY

7thSEMESTER PROJECT MEMBERS:

1-DEEPAK RANJAN SINGH0701032015

2-GHANSHYAM0701032020

3-SATISH JOSHI - 0701032043

4-SHASHANK TIWARY0701032050


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INDEX

OBJECTIVE

INTRODUCTION

ABOUT THE POROJECT

TECHNOLOGY USED (DTMF SIGNALLING)

BLOCK DIAGRAM

MAIN CIRCUIT DIAGRAM

COMPONENT LIST WITH SPECIFICATION

MICROCONTROLLER(AT89C52C)

POWER SUPPLY

RELAY UNIT(SPDT)

DTMF(MT8870D/MT8870D-1)

VOICE RECORDING/PLAYBACK DEVICE(APR9600)

WORKING

APPLICATION

ADVANTAGE

DISADVANTAGE

FUTURE ADVANCEMENT


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OBJECTIVE: INDUSTRIAL AUTOMATION USING CELLPHONE.

INTRODUCTION: -In the present world of wireless technology everything is goingto be digital and wireless, and the cell phone is the key player in wireless technology today.

Industrial Automation is a field that requires a vast involvement in the safety and the security

aspects. The intensity towards this concept may vary according to the nature of the industry.

For industries that involve heavy and sophisticated installations such that of a chemical plant

etc, the security feature must be more intense as compared to less complicated industrial

plants. In any chemical plant Industrial automation not only helps in the efficient working of

the plant, but also the safety of the workers and the installations involved. In the proposeddesign, if any of these values exceeds beyond a particular limit, then immediately the entire

system will be shut down ensuring that any further damages are blocked.

Automation plays an important role in world economy and in daily experience. Engineers

combine automated devices with mathematical and organizational tools to create complex for

a rapidly expanding range of application and human activities. Human machine interface

(HMI) or computer interface (CHI),formerly known as man machine interface are usually

employed to communicate with PLCS and other computers, such as entering and monitoring

temperature or pressure for further automated control or emergency response. Service

personnel who monitor and control these interfaces are often referred to as manufacturing

environments; these roles are called operators or variations on this.

And today technology made the possessing of a mobile, considered as a basic commodity and

the trends in wireless technology changing day-by-day and today the working is going on

how to develop remote devices without the presence of man and to reduce to the time factor

and labor, and our project belongs to that race and by using it we can control any electronic

devices through a touch cell phone, with one Call.


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ABOUT THE POROJECT

In this project, the electronic devices are controlled by a mobile phone that makes a call to themobile phone attached to the devices. In the course of a call, if any button is pressed, a tone

corresponding to the button pressed is heard at the other end of the call. This tone is called

dual-tone multiple-frequency (DTMF) tone. The devices perceive this DTMF tone to

perform required changes for controlling various parameters of the industry.

The received tone is processed by the ATmega16microcontroller with the help of DTMF

decoder MT8870. The decoder decodes the DTMF tone into its equivalent binary digit and

this binary number is sent to the microcontroller.The microcontroller is pre programmed to

take a decision for any given input and outputs its decision to devices in order to control the

dc motor & cooling fan. The mobile that makes a call acts as a remote. So this simpleautomation project does not require the construction of receiver and transmitter units.

DTMF signalling is used for telephone signalling over the line in the voice frequency band to

the call switching centre. The version of DTMF used for telephone tone dialling is known as

Touch-Tone.

DTMF assigns a specific frequency (consisting of two separate tones) to each key so that it

can easily be identified by the electronic circuit. The signal generated by the DTMF encoder

is a direct algebraic summation, in real time, of the amplitudes of two sine (cosine) waves of

different frequencies, i.e., pressing 5 will send a tone made by adding 1336 Hz and 770 Hz

to the other end of the mobile phone.


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TECHNOLOGY USED

Dual-Tone Multi-Frequency (DTMF):- Dual-tone multi-frequency (DTMF)signaling is used for telecommunication signaling over analog telephone lines in the voice-

frequency band between telephone handsets and other communications devices and the

switching center. The version of DTMF used for telephone tone dialing is known by the

trademarked term Touch-Tone (canceled March 13, 1984) and is standardized by ITU-T

Recommendation Q.23. It is also known in the UK as MF4. Other multi-frequency systems

are used for signaling internal to the telephone network.

As a method of in-band signaling, DTMF tones were also used by cable televisionbroadcasters to indicate the start and stop times of local commercial insertion points during

station breaks for the benefit of cable companies. Until better out-of -band signaling

equipment was developed in the 1990s, fast, unacknowledged, and loud DTMF tone

sequences could be heard during the commercial breaks of cable channels in the United

States and elsewhere.

Telephone Keypad

The contemporary keypad is laid out in a 3x4 grid, although the original DTMF keypad had

an additional column for four now-defunct menu selector keys. When used to dial a telephone

number, pressing a single key will produce a pitch consisting of two simultaneous pure tone

sinusoidal frequencies.The row in which the key appears determines the low frequency, and

the column determines the high frequency. For example, pressing the! 1! Key will result in a

sound composed of both a 697 and a 1209 hertz (Hz) tone. The original keypads had levers

inside, so each button activated two contacts. The multiple tones are the reason for calling the

system multi frequency.These tones are then decoded by the switching center to determinewhich key was pressed.


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A DTMF Telephone Keypad


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BLOCK DIAGRAM OF CIRCUIT

DISCRIPTION: - As shown in the above block diagram, first block is the cell phone .so,it acts as a DTMF generator with tone depending upon key pressed. DTMF Decoder, i.e., IC

CM8870 decodes the received tone & gives binary equivalent of it to the microcontroller.

The controller is programmed such that appropriate output is given to relay which will drive

the DC Motor & cooling fan. APR9600 provide voice acknowledgement that is status of

device.


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MAIN CIRCUIT DIAGRAM


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COMPONENT LIST WITH SPECIFICATION

AT89C51 MICROCONTROLLER:

Features:

Compatible with MCS-51 Products

4K Bytes of In-System Reprogrammable Flash Memory

Endurance: 1,000 Write/Erase Cycles

Fully Static Operation: 0 Hz to 24 MHz

Three-level Program Memory Lock

128 x 8-bit Internal RAM

32 Programmable I/O Lines

Two 16-bit Timer/Counters

Six Interrupt Sources

Programmable Serial Channel Low-power Idle and Power-down Modes

Description:

The AT89C51 is a low-power, high-performance CMOS 8-bit microcomputer with 4K bytes

of Flash programmable and erasable read only memory (PEROM). The device is

manufactured using Atmels high-density non-volatile memory technology and is compatible

with the industry-standard MCS-51 instruction set and pin out. The on-chip Flash allows the

program memory to be reprogrammed in-system or by a conventional non-volatile memory

programmer. By combining a versatile 8-bit CPU with Flash on a monolithic chip, the Atmel

AT89C51 is a powerful microcomputer which provides a highly-flexible and cost-effective

solution to many embedded control applications.


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POWER SUPPLY:

The 230V AC mains is stepped down by transformer X1 to deliver the secondary output of

9V, 500 mA . This voltage is converted to DC voltage using a Bridge Rectifier.

CIRCUIT DAIGRAM:

RESISTORS:

R16: 470ohm

CAPACITORS:

C16: 1000F

C15: 0.1F

DIODES:

LED3: WORK AS LED


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RELAY (SPDT): A relay is an electrically operated switch.

Superior high-frequency characteristics, such as an isolation of 30 DB min., insertionloss of 0.5 dB max., and V.SWR of 1.5 max. at 2.6 GHz.

Surface-mounting terminals and superior high frequency Characteristics combined

using semi triplet strip transmission lines.

Miniature dimensions of 20 x 8.6 x 8.9 mm (L x W x H).

Choose from a line-up that includes single-winding latching models (200 mW),

double-winding latching models (360 mW), and models with a reverse contact

arrangement.

Series includes models with an E-shape terminal structure (same as existing models),and models with a Y-shape terminal structure, allowing greater freedom with PCB

design.

Models with 75- impedance and models with 50- impedance areavailable.

Advantages of relays:

Relays can switch AC and DC, transistors can only switch DC.

Relays can switch high voltages, transistors cannot.

Relays are a better choice for switching large currents(> 5A).

Relays can switch many contactsat once.

Disadvantages of relays:

Relays are bulkierthan transistors for switching small currents.

Relays cannot switch rapidly(except reed relays), transistors can switch

many times per second.

Relays use more powerdue to the current flowing through their coil.

Relays require more current than many ICs can provideso a low power transistor

may be needed to switch the current for the relay's coil.


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DTMF (DUAL TONE MULTI FREQUENCY):

Dual Tone Multi-Frequency, or DTMF, is a method for instructing a telephone switching

system of the telephone number to be dialed, or to issue commands to switching systems

or related telephony equipment.

The version of DTMF used for telephone tone dialing is known by the trademarked term

Touch-Tone (canceled March 13, 1984), and is standardized by ITU-T Recommendation

Q.23. It is also known in the UK as MF4.

The MT8870D/MT8870D-1 is a complete DTMF receiver integrating both the band splitfilter and digital decoder functions. The filter section uses switched capacitor techniques

for high and low group filters; the decoder uses digital counting techniques to detect and

decode all 16 DTMF tone pairs into a 4-bit code. External component count is minimized

by on chip provision of a differential input amplifier, clock oscillator and latched three-

state bus interface.

FEATURES:

Low MIPS: 0.25 /0.35 MIPS for 10 ms and 5 ms frame size versions respectively

Designed as a telecom system component rather than a stand-alone algorithm.

Can be configured on the fly, and such parameters as twists, frequency acceptance,

spectrum Cleanness, and signal duration thresholds can be altered during a call.

Does not use notch filters to suppress dial tone, so it tolerates relatively high-level

echo dial tone (1520 dB above DTMF level) even if its frequencies are quite

different from the nominal, exceeding standard +/-0.5% tolerance.


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CIRCUIT DIAGRAM:

COMPONENTS SPECIFICATION:

RESISTORS:

R5: 470K

R6: 100K

R7: 220K

R4, R5, R6, R7, R8: 1K

CAPACITORS:

C11: 0.1F

C12: 0.22F


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VOICE RECORDING/PLAYBACK DEVICE(APR9600)

General Description:

The APR9600 device offers true single-chip voice recording, non-volatile storage, and

playback capability for 40 to 60 seconds. The device supports both random and sequential

access of multiple messages. Sample rates are user-selectable, allowing designers to

customize their design for unique quality and storage time needs. Integrated output amplifier,

microphone amplifier, and AGC circuits greatly simplify system design. the device is ideal

for use in portable voice recorders, toys, and many other consumer and industrial

applications. APLUS integrated achieves these high levels of storage capability

by using its proprietary analog/multilevel storage technology implemented in an advanced

Flash non-volatile memory process, where each memory cell can store 256 voltage levels.

This technology enables the APR9600 device to reproduce voice signals in their natural form.

It eliminates the need for encoding and compression, which often introduce distortion.

Message Management:Playback and record operations are managed by on chip circuitry. There are severalavailable messaging modes depending upon desired operation. These messagemodes determine message management style, message length, and external partscount. Therefore, the designer must select the appropriate operating mode beforebeginning the design. Operating modes do not affect voice quality; for informationon factors affecting quality refer to the Sampling Rate & Voice Quality section.The device supports three message management modes (defined by the MSEL1,MSEL2 and /M8_Option pins shown in Figures 1 and 2):

Random access mode with 2, 4, or 8 fixed-duration messages Tape mode, with multiple variable-duration messages, provides

two options:- Auto rewind- Normal

Modes cannot be mixed. Switching of modes after the device has recorded an initialmessage is not recommended. If modes are switched after an initial recording hasbeen made some unpredictable message fragments from the previous mode mayremain present, and be audible on playback, in the new mode. These fragments willdisappear after a record operation in the newly selected mode. Table 1 defines thedecoding necessary to choose the desired mode. An important feature of theAPR9600 message management capabilities is the ability to audibly prompt the userto changes in the devices status through the use of beepssuperimposed on thedevices output. This feature is enabledby asserting a logic high level on the BE pin.


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USED MODE:

Random Access Mode:

Random access mode supports 2, 4, or 8 messages segments of fixed duration. Assuggested recording or playback can be made randomly in any of the selectedmessages. The length of each message segment is the total recording lengthavailable (as defined by the selected sampling rate) divided by the total number ofsegments enabled (as decoded in Table1). Random access mode provides easyindexing to message segments.


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WORKING

In this project to perform automation two cell phones are used out of which one is present at

the field side i.e: receiver side with auto call receiving mode and the second one is present on

the sender side. When we make a call to the cell phone present on the field side then it is

received due to auto receiving mode and after that to control the various machineries we

press a key. Whenever a key is pressed by the operator a frequency is generated which is the

combination of higher and lower frequency having range of voice frequency at the receiver

side i.e.: detected by the mobile phone present on the receiver side and through the head

phone attached to it this frequency is moved to the DTMF (MT8870D/MT8870D-1)

decoderwhich converts this analogue signal into binary digit i.e.; O1, O2, O3, O4. Now these

binarydigits are send to the microcontroller AT89c51 through pin no. P2.0 P2.3. This

microcontroller has additional reset circuitry for resetting of the microcontroller. The output

from the microcontroller is used to operate the buzzer, lamp, DC motor and cooling fan. The

output from the microcontroller is obtained from the pin no. P3.0 P3.3. And this output is

taken to operate above mentioned four loads through relay. Relay works as a automatic

switch which is not directly connected to the microcontroller. Firstly the relay is connected to

the collector part of the npn transistor and the base of that transistor is connected to the

output ports of the microcontroller i.e.: first the output is moved to the npn transistor and after

that the enhanced signal obtained at the collector end of the transistor operate the relay to turn

ON or OFF the DC motor, cooling fan, buzzer, lamp. Here the microcontroller and the

DTMF decoder are operated by the +5 volt DC supply which is derived from the power

supply circuitry which takes 230v; 50Hz Single phase. Here, Voice acknowledgement is

provided by the APR9600 (IC2). It is a single-chip voice recording and playback device thatcan record and play multiple messages at random or in sequential mode for 60 seconds. The

user can select sample rates with corresponding- quality recording lengths. Microphone

amplifier, automatic gain control (AGC) circuits, internal ant aliasing filter, internal output

amplifier and message management are some of the features of the APR9600. Here the

APR9600 is configured in random-access mode, which supports two, four and eight messages

of fixed durations. The length of each message is the total recording length available divided

by the total number of memory segments/tracks enabled. Audio processor APR9600 can store

up to eight voice messages. Port P0 pins and P2.7 are configured to communicate with IC2.

Port P0 pins trigger selection of the message. Port pin P2.7 is the input signal to identify

whether the voice message is playing or not. Pins P3.0 through P3.5 of Port P3 control the

devices with the help of relays RL1 through RL6 via relay driver IC4. A speaker is connected

to IC2 for audio output. The speaker output drives the mic input of the mobile for audio

acknowledgement. An electric microphone MIC1 is connected to IC2 to record the voice in

IC2. LED2 flashes to show the busy status of IC2 during recording and playback. The audio

messages to be recorded in APR9600, by using trigger switches S9 through S16, are shown in

Table III. SPST switch S19 is closed for recording and switch S19 is opened for playback.

The 230V AC mains is stepped down by transformer X1 to deliver the secondary output of

9V, 500 mA . This voltage is converted to DC voltage using a Bridge Rectifier.


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APPLICATIONS:

Automated teller machines (ATM).

Automated telephone switchboards and answering machines.

Medical processes such as primary screening in radiography and laboratory analysis

of human genes, sera, cells and tissues.

Automation increases quality & flexibility in the manufacturing process.

Automated guided vehicles with natural features navigation.

Automation is also used in manufacturing of industrial chemicals & all form of metal

works.

Automated machine installation.

ADVANTAGES:

Replacing human operators in task that involve hard physical or monotonous work.

Replacing humans in tasks that should be done in dangerous environments (i.e.; fire,

space, volcanoes, nuclear facilities, underwater, etc.)

Making tasks that are beyond the humans capabilities such as handling to heavyloads, too large objects, too hot or too cold substances or the requirements to make

things too fast or too slow.

Economy improvement sometimes & some kinds of automation implies improves in

economy of enterprises, society or most of humanities for example, when an

enterprises that has invested in automation technology recovers its investment, when a

state or country increases is income due to automation like Germany or Japan in 20 th

century or when the humankind can use the internet which is turn use satellite & other

automated engines.


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DISADVANTAGES:

Technology limits current technology is unable to automate all the desired tasks.

Unpredictable development costs. The research & development cost of automating a

process is difficult to predict accurately beforehand. Since this cost can have a large

impact of profitability it is possible to finish automating a process only to discover

that there are no economic advantages in doing so.

Initial costs are relatively high. The automation of a new product required a huge

initial investments in comparison with the unit cost of the product, although the cost

of automation is Rs. 8300 .

Spread in many product batches. The automation of a plant required a great initial

investment too, although this cost is spread in the products to be produced.

FUTURE ADVANCEMENT:

Since the turn of the century, the global recession has affected most businesses, including

industrial automation. After four years of the new millennium, here are my views on the

directions in which the automation industry is moving. After several years of stagnation the

industrial automation market is growing. During the coming year several new technologies

will emerge if we look at the new technology that are coming up in the field of industrial

automation we find a complete shift from traditional practices to more sophisticated and

developed technologies.

Industrial Wireless:Wireless is an enabling technology for end users. Application ofwireless technology is broader than the current market buzz around process-focused device

networks. Reliability is the key for wireless sensor networks, being addresses by combining

meshing with spread spectrum technology. Again Latency, Security, Power, Throughput are

the important factors contributing to the rapid use of industrial wireless technology. As with

the growing use of technology is making it imperative for the use of best technology that is

available.

The spread of new wireless technology in the industrial environment will bring the ability to

do things that were inconceivable before. This will bring changed work processes and new

skill sets that may not simply extend from current habit-patterns. The future values ofwireless in the factory and process plant are yet to be imagined. Im willing to bet that


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advanced and innovative wireless products, if introduced rapidly at a breakthrough price,

would sweep industrial automation markets; end-users would gobble them up. It could spark

a new phase of growth that will re-energize industrial automation.

Embedded Intelligence & M2M: Used in everything from consumer electronics toindustrial equipment, embedded systems - small, specialized computer systems stored on a

single microprocessor - are playing a major role in the growth of the Internet and the boom of

wireless communication channels. Now in industry it has more use with the use of wireless

technologies. Embedded intelligence and connectivity is what M2M and pervasive computing

are all about. The information coming from a device can be just as valuable, if not more

valuable, than the device itself: for example, when it was installed and by whom, uptime &

downtime, critical specifications, diagnostics, availability of spares, replacement alternatives,

repair instructions, usage patterns, and more. All this invisible machine activity makes theinformation about assets, costs, and liabilities vastly more visible to managers and to the

decision-making process.

M2M makes the information about assets, costs, and liabilities vastly more visible to

managers and to the decision-making process. This will unleash a wave of productivity and

efficiencies previously unseen. Smart services represents the biggest organic growth

opportunity for industrial automation equipment suppliers.

Web Services & Applications Integration: Web services differ from Webapplications in that they generally involve application-to-application communication, and are

not intended to be accessed via a Web browser. Instead, clients can be written in any

language that supports HTTP and SOAP. A client transmits a message or remote method call

to a Web service, which processes the message and returns a response to the client. Web

services do not usually have any sort of user interface built in, and it is generally up to the

client to process input and display output.

Web delivery of process and business data enhances collaboration between work groups and

multi-location plants across the enterprise. Web Services, Supply Chain Management,

Customer Relationship Management, Enterprise Application Integration and a plethora of

other software tools and services will be integrated to facilitate optimal decision-making at all

levels.

Real-time Information to Boost Productivity:Real-time enterprise applications are cutting

through several layers of previous inefficiency, allowing all segments of a business to interact

in ways that were previously unthinkable. The goal of the real-time enterprise is to act onevents as they happen. It is all the old concepts of customer-driven marketing, on-line process


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automation, just in time delivery, and tactical business adaptation all rolled into one. It's

about getting information in and out quickly, monitoring the business as it happens, and

making quick, effective, agile decisions.

Robots are Coming: The introduction of robots with integrated vision and touchdramatically changes the speed and efficiency of new production and delivery systems.

Robots have become so accurate that they can be applied where manual operations are no

longer a viable option. The biggest change in industrial robots is that they will evolve into a

broader variety of structures and mechanisms. In many cases, configurations that evolve into

new automation systems wont be immediately recognizable as robots. For example, robots

that automate semiconductor manufacturing already look quite different from those used in

automotive plants.

To implementing these directions demands management and leadership abilities that aredifferent from old, financially-driven models. In the global economy, automation companies

have little choice - they must find more ways and means to expand globally. To do this they

need to minimize domination of central corporate cultures, and maximize responsiveness to

local customer needs. Multi-cultural countries, like the U.S., will have significant advantages

in these important business aspects.

In the new and different business environment of the 21st century, the companies that can

adapt, innovate and utilize global resources will generate significant growth and success.

industrial automation using cell phone progress

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