rfid based industrial inventory control system

“RFID BASED INDUSTRIAL INVENTORY

CONTROL SYSTEM”

A Major Project Report

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF

Bachelor of Technology

In

INSTRUMENTATION AND CONTROL ENGINEERING

By

SAGAR BARASARA (09BIC002)

MANISH JHURANI (09BIC014)

KALPESH DHAPA (09BIC015)

UNDER THE GUIDANCE OF

PROF. VISHAL VAIDYA

DEPARTMENT OF ELECTRICAL ENGINEERING

INSTITUTE OF TECHNOLOGY

NIRMA UNIVERSITY Ahmedabad 382 481

May 2013

CERTIFICATE

This is to certify that the Major Project Report entitled “RFID Based Industrial

Inventory Control System” submitted by Sagar Barasara (09BIC002), Manish

Jhurani (09BIC014) & Kalpesh Dhapa (09BIC015) as the partial fulfillment of

the requirements for the award of the degree of Bachelor of Technology in

Instrumentation and Control Engineering, Institute of Technology, Nirma

University is the record of work carried out by them under my supervision and

guidance. The work submitted in our opinion has reached a level required for being

accepted for the examination. The results embodied in this project work to the best

of my knowledge have not been submitted to any other University or Institution for

award of any degree or diploma.

Prof. Vishal Vaidya

Project Guide

Prof. Dipak M Adhyaru

Section Head (IC)

Prof. P.N.Tekwani

HOD (EE)

Date:

Page i

Acknowledgement

We would deeply like to express our sincere gratitude towards project guide Prof.

Vishal Vaidya and faculty members of our panel who have guided until the

completion of the project. We also extend our thanks towards our Section Head Dr.

D M Adhyaru and all the staff, Department of Instrumentation and Control

Engineering, Institute of Technology, Nirma University for their assistance during

the project whether it was a technical help or concerned with providing facilities

for internet, implementing and simulating the ideas of the project. We would also

like to thank the faculty members of Workshop- Prof. Naik, Prof. I.R.Patel, Prof.

Narendra Patel, Prof. Mihir Chauhan who helped us a lot in building the

mechanical structure of Grappler robot. Their excessive support has been the

source of motivation to perform our best regarding the project.

Moreover, we are highly thankful to our classmates who were there all the times,

backing us up and their undue support has been the pushing drive for us to

complete the project within time.

Sagar Barasara(09BIC002)

Manish Jhurani(09BIC014)

Kalpesh Dhapa(09BIC015)

Page ii

Abstract

The project model is based on a typical open loop system. When a particular

coloured RFID card is swiped in the control room, the information about the same

is transmitted wirelessly by the microcontroller in the control room to the

microcontroller on the Grappler robot on the field. The robot then picks up the

same coloured object from the inventory, places it on the conveyor belt and returns

to its initial position. The object on the conveyor belt is now directed to its

appropriate position by the actuators on the conveyor belt. This system can be used

to load the finally packed products in the manufacturing industry into the

transportation trucks as well as to access the various items in the inventory to use

during the manufacturing process. The cost of human labour can thus be reduced

as this process becomes automatic.

Page iii

List of Figures

1.1: Workers taking out stock from the inventory …………………………………3

2.1: Mechanical Structure of Grappler Robot ……………………………………..5

2.2: Vertical Mechanism……………………………………………………………6 2.3: Horizontal Mechanism………………………………………………………...7 2.4: Clamper Assembly…………………………………………………………….8 2.5: The Inventory………………………………………………………………….9

3.1: Control Panel…………………………………………………………………11

4.1: Transmitter connection……………………………………………………….13

4.2: Receiver connection……………………………………………………….…14

5.1: Conveyor Belt………………………………………………………………...17

6.1: 5V Power Supply……………………………………………………………..19

6.2: 12V Power Supply……………………………………………………………19

7.1: DC Motor Internal Diagram………………………………………………….22

8.1: Block Diagram………………………………………………………………..23

8.2: Grappler Circuit Diagram…….………………………………………………23

9.1: 315/434 MHz ASK Transmitter…….……………………………………….49

9.2: ST-TX01 Pin Diagram……………………………………………………….50

9.3: Pin Dimensions of ST-TX01…………………………………………………51

9.4: ST-RX02 Receiver IC………………………………………………………..52

9.5: ST-RX02 Pin Diagram……………………………………………………….52

9.6: Pin Dimensions of ST-RX02…………………………………………………53

9.7: Temperature Characteristics of ST-RX02……………………………………54

9.8: RFID Reader RKI-1512……………………………………………………...61

9.9: RKI-1512 Pin Diagram………………………………………………………62

9.10: RKI-1512 Connections……………………………………………………...63

9.10: Pin diagram of L298………………………………………………………...64

9.11: Circuit Diagram for L298 Motor Driver……………………………………65

9.12: LM7805/12 Packages……………………………………………………….67

Page iv

List of Tables 9.1: Electrical Characteristics of ST-TX01……………………………………….50

9.2: Pin Dimensions of ST-TX01…………………………………………………51

9.3: Electrical Characteristics of ST-RX02……………………………………….53

9.4: PIC 16F877A Features……………………………………………………….59

9.5: L298 Pin Functions…………………………………………………………...65

9.6: L298 Operation………………………………………………………………66

9.7: LM7805 Electrical Characteristics…………………………………………..68

9.8: LM7812 Electrical Characteristics…………………………………………..69

Page v

CONTENTS

Acknowledgement……………………………………………………………...i

Abstract.………………………………………………………………………..ii

List of Figures…………………………………………………………………iii

List of Tables…………………………………………………………………..iv

Contents………………………………………………………………………...v

Chapter 1: Introduction 1

1.1 Inventory……………………………………………………………...1

1.2 Motivation…………………………………………………………….3

Chapter 2: Mechanical Structure 4

2.1 Vertical Motion……………………………………………………...6

2.2 Horizontal Motion…………………………………………………...7

2.3 Clamper Assembly…………………………………………………..8

2.4 Inventory…………………………………………………………….9

Chapter 3: Control Panel 10

Chapter 4: Wireless Transmission and Reception 12

4.1 Transmitter………………………………………………………...13

4.2 Receiver……………………………………………………………14

4.3 Encoder and Decoder……………………………………………...15

Page vi

Chapter 5: Distribution 16

Chapter 6: Power Supply 18

Chapter 7: DC Motor 20

7.1 Connection Types………………………………………………………….20

Chapter 8: Circuit Diagram and Code 23

8.1 Circuit Diagram…………………………………………………..23

8.2 Code for Control Panel…………………………………………...24

8.3 Code for Grappler robot………………………………………….31

Appendix 48

References 70

CHAPTER 1

Introduction

1.1 INVENTORY:

Inventory is the total amount of goods and/or materials contained in a

store or factory at any given time.

A canned food manufacturer's materials inventory includes the

ingredients to form the foods to be canned, empty cans and their lids

(or coils of steel or aluminum for constructing those components),

labels, and anything else (solder, glue, etc.) that will form part of a

finished can.

The firm's work in process includes those materials from the time of

release to the work floor until they become complete and ready for

sale to wholesale or retail customers.

This may be vats of prepared food, filled cans not yet labeled or sub-

assemblies of food components.

It may also include finished cans that are not yet packaged into

cartons or pallets.

Its finished goods inventory consists of all the filled and labeled cans

of food in its warehouse that it has manufactured and wishes to sell to

food distributors (wholesalers), to grocery stores (retailers), and even

Chapter 1: Introduction

Page 2

perhaps to consumers through arrangements like factory stores and

outlet centers.

Similarly, an automobile maker’s inventory includes various parts of

the automobile like the doors, bonnet, lights, seats, etc.

The access to the inventory for the materials stored in there can be

automatic or manual.

Building an autonomous system can ultimately reduce the cost of

human labour in the long run.

Moreover, this system is robust and can work in the range of 100

meters.

THE REASONS FOR KEEPING STOCK

There are four basic reasons for keeping an inventory:

1. Time - The time lags present in the supply chain, from supplier to user at

every stage, requires that you maintain certain amounts of inventory to use

in this lead time. However, in practice, inventory is to be maintained for

consumption during 'variations in lead time'. Lead time itself can be

addressed by ordering that many days in advance.

2. Uncertainty - Inventories are maintained as buffers to meet uncertainties in

demand, supply and movements of goods.

3. Economies of scale - Ideal condition of "one unit at a time at a place where

a user needs it, when he needs it" principle tends to incur lots of costs in

terms of logistics. So bulk buying, movement and storing brings in

economies of scale, thus inventory.

4. Appreciation in Value - In some situations, some stock gains the required

value when it is kept for some time to allow it reach the desired standard for

consumption, or for production. For example; beer in the brewing industry

Chapter 1: Introduction

Page 3

Fig 1.1: Workers taking out stock from the inventory

1.2 MOTIVATION:

Recently, we visited the Adani Wilmar Limited which manufactures cooking

oil.

The entire production facility was automatic in the industry.

The only problem which we noticed was that the finally packaged products

were stored in the storehouse manually.

Also, the loading of the finally manufactured products kept in the storehouse

into the trucks used for transportation was done manually.

This involved a lot of human effort as well as increase of cost and wastage

of time.

So, we decided to make a model so that this process can also become

autonomous.

CHAPTER 2

Mechanical Structure

The main task of picking up the object from the inventory and placing it on

the conveyor belt is done by the Grappler robot.

The Grappler robot had to be made such that it becomes robust and that it

should not bend due to weight.

Moreover, it should have been a light weighted robot so that it could be

easily put into motion.

So, we decided to make the body of the robot with Aluminium plate as it

catered to all our requirements.

The entire structure was made by us by working intensively for 15 hours in

the college workshop.

The Grappler robot is the heart of our project.

The Grappler is a simple four wheeled autonomous robot that works on the

instructions provided by its on-board microcontroller.

All the electronic circuits, motor drivers, wireless data receiver, decoder,

antenna and power supplies are mounted on its body.

In order to move to different columns of the inventory, it is provided with

four 30 rpm motors.

Chapter 2: Mechanical Structure

Page 5

Fig 2.1: Mechanical Structure of Grappler Robot


Page 6

2.1 Vertical Motion:

For moving up and down a column, a 4-pulley lift is made.

The lift houses a wooden bucket on which the slider is supported.

The lift system works when the string winds and unwinds around a wooden

support.

The height to which it should be lifted is decided by the timing calibration.

The lift motor is of 10 rpm.

Fig2.2: Vertical Mechanism


Page 7

2.2 Horizontal motion:

For picking the object out of the box, horizontal motion is required.

This is achieved by using a simple drawer channel used in table drawers.

The motor used to slide the clamper assembly had to be light in weight

otherwise it would have been difficult to lift it.

So, a medium torque, light weight 60 rpm motor is used here.

Also, due to the in and out motion of the slider, imbalance can arise.

Hence, a counterweight is kept at the back side of the slider bucket.

This helps in smooth working of the system.

Fig2.3: Horizontal Mechanism


Page 8

2.3 Clamper Assembly:

To pick up the object and hold it, a clamper assembly is made.

Two light weight Aluminium strips form the fingers of the clamper.

Since Aliminium is smooth, there was a chance of the object falling down

from its clasp.

So, rubber coating is done on its inner surface.

A medium torque, light weight 45 rpm motor is used to rotate one strip of

Aluminium.

The other one rotates due to the gear assembly.

Fig2.4: Clamper Assembly


Page 9

2.4 Inventory

The model inventory made by us consists of different shelves where the

objects are placed.

The inventory shelves are made of wood.

Each section is of 25x15 cm.

The Grappler picks up the required coloured object from the inventory.

Fig2.5: The Inventory

CHAPTER 3

Control Panel

Control panels are found in factories to monitor and control machines or

production lines. Old control panels are most often equipped with push

buttons and analog instruments, whereas today in many cases touch-

screens are used for monitoring and control purposes.

A similar model of a control panel is made by us.

The information regarding which object is to be picked up is passed from

here to the Grappler robot.

Different coloured RFID cards are placed in a tray.

The user can pick up any desired colour card and swipe it once over the

RFID sensor module.

Each card corresponds to a specific number from 1 to 6.

The RFID sensor sends the information to PIC16f877A microcontroller.

The microcontroller then searches in its code and assigns the card’s

particular number from 1 to 6.

This data is then sent to the encoder to encode it.

The encoder then passes on this data to the transmitter IC to transmit

wirelessly at 433 MHz through the antenna.

The receiver IC on the Grappler robot receives the data and decoder is used

to decode it.

Chapter 3: Control Panel

Page 11

Fig3.1: Control Panel

CHAPTER 4

WIRELESS TRANSMISSION AND

RECEPTION

In industry, the control room is actually far away from the field devices.

The information about the task to be performed or the reading to be noted is

transmitted from the control room to the field.

We have achieved this with the help of wireless transmission at 433 MHz

frequency.

The information about which coloured object is to be picked up by Grappler

robot is transmitted to it wirelessly once the RFID card is swiped and its

colour is decided by the microcontroller in the control room.

The microcontroller on the Grappler robot receives this data and works

accordingly. The RX – ASK is an ASK Hybrid receiver module. It is an

effective low cost solution for using 433 MHz.

The TX-ASK is an ASK hybrid transmitter module. TX-ASK is designed by

the saw resonator, with an effective low cost, small size and simple to use

for designing.

Chapter 4: Wireless Transmission and Reception

Page 13

4.1 Transmitter:

ST-TX01

Typical Application:

Fig4.1: Transmitter connection

Applications

Wireless security systems

Car Alarm systems

Remote controls.

Sensor reporting

Automation systems


Page 14

4.2 Receiver

ST-RX02

Applications

Car security system

Wireless security systems

Sensor reporting

Automation system

Remote Keyless entry

Fig4.2: Receiver connection


Page 15

4.3 Encoder and Decoder

Each of the RFID cards is assigned a number from 1 to 6.

Depending on the RFID card that is swiped, the particular number

corresponding to that card is transmitted wirelessly.

But this number is encoded before transmission. On reception, it is decoded

and the information is passed on to the microcontroller. It then decides

which coloured object is to be picked up.

The Grappler robot then performs the task of picking up the same coloured

object, placing it on the conveyor belt and returning back to its initial

position.

HT12E is the encoder IC whereas HT12D is the decoder IC.

CHAPTER 5

DISTRIBUTION

Distribution is the final stage of the process.

Once the Grappler robot picks up the object from its position in the

inventory, it places it on the conveyor belt besides the inventory.

The main objective of distribution is performed here.

The conveyor belt is made by winding a leather strap on two kite string

spools.

A power window motor is used to run the conveyor belt.

The motor is connected to the spool and is powered by 12V supply.

The objects in the inventory are distributed with the help of actuator on the

conveyor belt.

If the object is taken from the first column of the inventory, it is knocked

down by the actuator and it falls in the bucket.

If it is taken from the second column of the inventory, the actuator does not

work and hence the object falls down on the other side of the conveyor belt

in the second bucket.

Thus, the task of distributing objects to the specified places is accomplished.

After placing the object on the conveyor belt, the Grappler robot returns to

its initial position and the entire process can be performed again.

Chapter 5: Distribution

Page 17

Fig5.1: Conveyor Belt

CHAPTER 6

Power Supply

A regulated power supply is an embedded circuit, or stand alone unit, the

function of which is to supply a stable voltage (or less often current), to a

circuit or device that must be operated within certain power supply limits.

The output from the regulated power supply may be alternating or

unidirectional, but is nearly always DC.

The type of stabilization used may be restricted to ensuring that the output

remains within certain limits under various load conditions, or it may also

include compensation for variations in its own supply source.

The latter is much more common today.

Modern regulated supplies mostly use a transformer, silicon diode bridge

rectifier, reservoir capacitor and voltage regulator IC.

There are variations on this theme, such as supplies with multiple voltage

lines, variable regulators, power control lines, discrete circuits and so on.

Switched mode regulator supplies also include an inductor.

In our circuit, we have used two 5V power supplies for the control panel

using the LM-7805 IC.

Also, we have used six 5V power supplies using LM-7805 IC and four 12V

power supplies using LM-7812 IC for powering the Grappler robot.

Chapter 6: Power Supply

Page 19

Fig6.1: 5V Power Supply

Fig6.2: 12V Power Supply

CHAPTER 7

DC Motor

A DC motor is a mechanically commutated electric motor powered from direct

current (DC). The stator is stationary in space by definition and therefore so is its

current. The current in the rotor is switched by the commutator to also be

stationary in space. This is how the relative angle between the stator and rotor

magnetic flux is maintained near 90 degrees, which generates the maximum

torque.

DC motors have a rotating armature winding but non-rotating armature magnetic

field and a static field winding or permanent magnet. Different connections of the

field and armature winding provide different inherent speed/torque regulation

characteristics. The speed of a DC motor can be controlled by changing the voltage

applied to the armature or by changing the field current. The introduction of

variable resistance in the armature circuit or field circuit allowed speed control.

Modern DC motors are often controlled by power electronics systems called DC

drives.

The introduction of DC motors to run machinery eliminated the need for local

steam or internal combustion engines, and line shaft drive systems. DC motors can

operate directly from rechargeable batteries, providing the motive power for the

first electric vehicles. Today DC motors are still found in applications as small as

toys and disk drives, or in large sizes to operate steel rolling mills and paper

machines.

7.1 Connection Types:

There are three types of electrical connections between the stator and rotor possible

for DC electric motors: series, shunt/parallel and compound ( various blends of

series and shunt/parallel) and each has unique speed/torque characteristics

appropriate for different loading torque profiles/signatures.

Chapter 7: DC Motor

Page 21

Series connection

A series DC motor connects the armature and field windings in series with a

common D.C. power source. The motor speed varies as a non-linear function of

load torque and armature current; current is common to both the stator and rotor

yielding I^2 (current) squared behavior. A series motor has very high starting

torque and is commonly used for starting high inertia loads, such as trains,

elevators or hoists. This speed/torque characteristic is useful in applications such

as dragline excavators, where the digging tool moves rapidly when unloaded but

slowly when carrying a heavy load.

With no mechanical load on the series motor, the current is low, the counter-EMF

produced by the field winding is weak, and so the armature must turn faster to

produce sufficient counter-EMF to balance the supply voltage. The motor can be

damaged by over speed. This is called a runaway condition.

Series motors called "universal motors" can be used on alternating current. Since

the armature voltage and the field direction reverse at (substantially) the same time,

torque continues to be produced in the same direction. Since the speed is not

related to the line frequency, universal motors can develop higher-than-

synchronous speeds, making them lighter than induction motors of the same rated

mechanical output. This is a valuable characteristic for hand-held power tools.

Universal motors for commercial power frequency are usually small, not more than

about 1 kW output. However, much larger universal motors were used for electric

locomotives, fed by special low-frequency traction power networks to avoid

problems with commutation under heavy and varying loads.

Shunt connection

A shunt DC motor connects the armature and field windings in parallel or shunt

with a common D.C. power source. This type of motor has good speed regulation

even as the load varies, but does not have as high of starting torque as a series DC

motor. It is typically used for industrial, adjustable speed applications, such as

machine tools, winding/unwinding machines and tensioners.

Compound connection

A compound DC motor connects the armature and fields windings in a shunt and a

series combination to give it characteristics of both a shunt and a series DC motor.

This motor is used when both a high starting torque and good speed regulation is

http://en.wikipedia.org/wiki/Utility_frequency

http://en.wikipedia.org/wiki/Traction_power_network

Chapter 7: DC Motor

Page 22

needed. The motor can be connected in two arrangements: cumulatively or

differentially. Cumulative compound motors connect the series field to aid the

shunt field, which provides higher starting torque but less speed regulation.

Differential compound DC motors have good speed regulation and are typically

operated at constant speed.

We have used DC Shunt Motor in our circuit.

Fig7.1: DC Motor Internal Diagram

CHAPTER 8

Circuit Diagram and Code

8.1 Circuit Connections

Fig 8.1: Block Diagram

Fig 8.2: Grappler Circuit Diagram

Chapter 8: Circuit Diagram and Code

Page 24

8.2 Control Panel Program:

#include<built_in.h>

void main() {

unsigned char uart_rd;

unsigned char i[] = "41009CF0E0CD";

unsigned char j[] = "41009CB17E12";

unsigned char k[] = "41009CD40900";

unsigned char l[] = "41009CA605AE";

unsigned char m[] = "41009CEA86B1";

unsigned char n[] = "840081067271";

unsigned char temp[13];

unsigned char v = 0;

ADCON1 = 0x04; // Configure as analog

CCP1CON =0x0c; // Disable comparator

TRISD = 0x00;

PORTD = 0x00;

TRISB = 0x00;

Trisc = 0x80; // To make Rx Pin as input

portb=0x00;

RCSTA = 0x90; // To make Receiving enable in continuous mode

TXSTA = 0x00;


Page 25

UART1_Init(9600); // Initialize UART module at 9600 bps

Delay_ms(100); // Wait for UART module to become stable

v1:

v=0;

do {

if (UART1_Data_Ready())

{ // If data is received,

uart_rd = UART1_Read(); // read the received data,

temp[v] = uart_rd; // temporary storing string

v = v +1;

if (v == 12)

{

temp[12] = 0;

v=0;


Page 26

if (temp[6] == i[6])

{

portb.f7=1;

portb.f6=1;

portb.f5=1;

portb.f4=1;

delay_ms(2000);

portb.f7=0;

portb.f6=0;

portb.f5=0;

portb.f4=0;

goto v1;

}

else if(temp[6] ==j[6])

{

portb.f7=1;

portb.f6=1;

portb.f5=1;

portb.f4=0;


Page 27

delay_ms(2000);

portb.f7=0;

portb.f6=0;

portb.f5=0;

portb.f4=0;

goto v1;

}

else if(temp[6] ==k[6])

{

portb.f7=1;

portb.f6=1;

portb.f5=0;

portb.f4=1;

delay_ms(2000);

portb.f7=0;


Page 28

portb.f6=0;

portb.f5=0;

portb.f4=0;

goto v1;

}

else if(temp[6] ==l[6])

{

portb.f7=1;

portb.f6=0;

portb.f5=1;

portb.f4=1;

delay_ms(2000);

portb.f7=0;

portb.f6=0;

portb.f5=0;

portb.f4=0;


Page 29

goto v1;

}

else if(temp[6] ==m[6])

{

portb.f7=0;

portb.f6=1;

portb.f5=1;

portb.f4=1;

delay_ms(2000);

portb.f7=0;

portb.f6=0;

portb.f5=0;

portb.f4=0;

goto v1;

}


Page 30

else if(temp[6]==n[6])

{

portb.f7=1;

portb.f6=1;

portb.f5=0;

portb.f4=0;

delay_ms(2000);

portb.f7=0;

portb.f6=0;

portb.f5=0;

portb.f4=0;

}

}

}

}while(1);

}


Page 31

8.3 Grappler Robot Program:

#include<built_in.h>

unsigned char i[] = "41009CF0E0CD";

unsigned char j[] = "41009CB17E12";

unsigned char k[] = "41009CD40900";

unsigned char l[] = "41009CA605AE";

unsigned char m[] = "41009CEA86B1";

unsigned char n[] = "840081067271";

unsigned char temp[13];

unsigned char v = 0;

void forward(unsigned int x)

{

int i;

portd.f0=0;

portd.f1=1;

portd.f2=0;

portd.f3=1;

portd.f6=0;

portd.f7=1;

portb.f0=1;

portb.f1=0;


Page 32

for(i=x/10;i>0;i--)

{

delay_ms(10);

}

portd.f0=0;

portd.f1=0;

portd.f2=0;

portd.f3=0;

portd.f6=0;

portd.f7=0;

portb.f0=0;

portb.f1=0;

delay_ms(500);

}

void reverse(unsigned int x)

{

int i;

portd.f0=1;

portd.f1=0;

portd.f2=1;

portd.f3=0;


Page 33

portd.f6=1;

portd.f7=0;

portb.f0=0;

portb.f1=1;

for(i=x/10;i>0;i--)

{

delay_ms(10);

}

portd.f0=0;

portd.f1=0;

portd.f2=0;

portd.f3=0;

portd.f6=0;

portd.f7=0;

portb.f0=0;

portb.f1=0;

delay_ms(500);

}

void pulleyup(unsigned int x)

{

int i;

portb.f6=1;


Page 34

portb.f7=0;

for(i=x/10;i>0;i--)

{

delay_ms(10);

}

portb.f7=0;

portb.f6=0;

delay_ms(500);

}

void pulleydown(unsigned int x)

{

int i;

portb.f6=0;

portb.f7=1;

for(i=x/10;i>0;i--)

{

delay_ms(10);

}

portb.f7=0;

portb.f6=0;


Page 35

delay_ms(500);

}

void sliderforward(unsigned int x)

{

int i;

portb.f4=1;

portb.f5=0;

for(i=x/10;i>0;i--)

{

delay_ms(10);

}

portb.f4=0;

portb.f5=0;

delay_ms(500);

}

void sliderreverse(unsigned int x)

{


Page 36

int i;

portb.f4=0;

portb.f5=1;

for(i=x/10;i>0;i--)

{

delay_ms(10);

}

portb.f4=0;

portb.f5=0;

delay_ms(500);

}

void clamperopen(unsigned int x)

{

int i;

portb.f3=1;

portb.f2=0;


Page 37

for(i=x/10;i>0;i--)

{

delay_ms(10);

}

portb.f3=0;

portb.f2=0;

delay_ms(500);

}

void clamperclose(unsigned int x)

{

int i;

portb.f3=0;

portb.f2=1;

for(i=x/10;i>0;i--)

{

delay_ms(10);

}

portb.f3=0;

portb.f2=0;


Page 38

delay_ms(50);

}

void main()

{

ADCON1 = 0x0F; // Configure as analog

CCP1CON =0x0c; // Disable comparator

TRISD = 0x00;

PORTD = 0x00;

TRISB = 0x00;

TRISC = 0xFF;

portb=0x00;

Delay_ms(100); // Wait for UART module to become stable

v1:

do

{

if (portc.f4==1 && portc.f5==1 && portc.f6==1 && portc.f7==1)

{


Page 39

clamperopen(170);

sliderforward(2000);

clamperclose(2000);

sliderreverse(2500);

forward(4500);

pulleyup(19000);


clamperopen(170);


clamperclose(2000);

reverse(4500);


Page 40

pulleydown(175000);

goto v1;

}

else if (portc.f4==0 && portc.f5==1 && portc.f6==1 && portc.f7==1)

{

pulleyup(13000);


clamperclose(2000);


forward(4500);


clamperopen(170);


Page 41


clamperclose(2000);

reverse(4500);

pulleydown(12500);

goto v1;

}


{

pulleyup(34500);

clamperopen(170);



Page 42

clamperclose(2000);


forward(4500);

pulleydown(21000);


clamperopen(170);


clamperclose(2000);

reverse(45000);

pulleydown(12500);

goto v1;

}


Page 43


{

forward(2000);

pulleyup(13000);

clamperopen(160);


clamperclose(2000);


forward(2500);


clamperopen(170);



Page 44

clamperclose(2000);

reverse(4500);

pulleydown(12500);

goto v1;

}


{

forward(2000);

pulleyup(34500);

clamperopen(170);



Page 45

clamperclose(2000);


forward(2500);

pulleydown(21000);


clamperopen(170);


clamperclose(2000);

reverse(4500);

pulleydown(11500);

goto v1;


Page 46

}


{

forward(2000);

pulleyup(34500);

clamperopen(150);


clamperclose(2000);


forward(2500);

pulleydown(21000);


Page 47


clamperopen(170);


clamperclose(2000);

reverse(4500);

pulleydown(12000);

goto v1;

}

} while(1);

}

APPENDIX

Transmitter IC(ST-TX01)

General Description:

The ST-TX01-ASK is an ASK Hybrid transmitter module. ST-TX01-ASK is

designed by the Saw Resonator, with an effective low cost, small size, and simple-

to-use for designing.

Frequency Range:315 / 433.92 MHZ.

Supply Voltage: 3~12V.

Output Power : 4~16dBm

Circuit Shape: Saw

Fig9.1: 315/434 MHz ASK TRANSMITTER

Appendix

Page 50

Pin Description:

Fig 9.2: ST-TX01 Pin Diagram

Table 9.1: Electrical Characteristics of ST-TX01

Appendix

Page 51

Pin Dimension:

Fig 9.3: Pin Dimensions of ST-TX01

Table 9.2: Pin Dimensions of ST-TX01

Appendix

Page 52

ST-RX02-ASK Receiver


The ST-RX02-ASK is an ASK Hybrid receiver module.

An effective low cost solution for using at 315/433.92 MHZ.

The circuit shape of ST-RX02-ASK is L/C.

Receiver Frequency: 315 / 433.92 MHZ

Typical sensitivity: -105dBm

Supply Current: 3.5mA

IF Frequency:1MHz

Features: Low power consumption.

Easy for application.

Operation temperature range : ﹣20℃～＋70℃

Operation voltage: 5 Volts.

Available frequency at: 315/434 MHz

Fig 9.4: ST-RX02 Receiver IC

Fig 9.5: ST-RX02 Pin Diagram

Appendix

Page 53

Table 9.3: Electrical Characteristics of ST-RX02

Fig 9.6: Pin Dimensions of ST-RX02

Appendix

Page 54

Fig 9.7: Temperature Characteristics of ST-RX02

Appendix

Page 55

Encoder (HT12E)

Features:

_ Operating voltage

_ 2.4V~5V for the HT12A

_ 2.4V~12V for the HT12E

_ Low power and high noise immunity CMOS technology

_ Low standby current: 0.1_A (typ.) at VDD=5V

_ HT12A with a 38kHz carrier for infrared transmission medium

_ Minimum transmission word

_ Four words for the HT12E

_ One word for the HT12A

_ Built-in oscillator needs only 5% resistor

_ Data code has positive polarity

_ Minimal external components

_ HT12A/E: 18-pin DIP/20-pin SOP package

Applications:

_ Burglar alarm system

_ Smoke and fire alarm system

_ Garage door controllers

_ Car door controllers

_ Car alarm system

_ Security system

_ Cordless telephones

_ Other remote control systems

General Description

The 212 encoders are a series of CMOS LSIs for remote control system

applications. They are capable of encoding information which consists of N

address bits and 12_N data bits. Each address/ data input can be set to one of the

two logic states. The programmed addresses/data are transmitted together with the

Appendix

Page 56

header bits via an RF or an infrared transmission medium upon receipt of a trigger

signal. The capability to select a TE trigger on the HT12E or a DATA trigger on

the HT12A further enhances the application flexibility of the 212 series of

encoders. The HT12A additionally provides a 38kHz carrier for infrared systems.

Operation:

The 212 series of encoders begin a 4-word transmission cycle upon receipt of a

transmission enable (TE for the HT12E or D8~D11 for the HT12A, active low).

This cycle will repeat itself as long as the transmission enable (TE or D8~D11) is

held low. Once the transmission enable returns high the encoder output completes

its final cycle and then stops.

Appendix

Page 57

Decoder (HT 12D)

Features:

_ Operating voltage: 2.4V~12V

_ Low power and high noise immunity CMOS technology

_ Low standby current

_ Capable of decoding 12 bits of information

_ Binary address setting

_ Received codes are checked 3 times

_ Address/Data number combination

_ HT12D: 8 address bits and 4 data bits

_ Built-in oscillator needs only 5% resistor

_ Valid transmission indicator

_ Easy interface with an RF or an infrared transmission medium

_ Minimal external components

_ Pair with Holtek_s 212 series of encoders

_ 18-pin DIP, 20-pin SOP package

Applications:

_ Burglar alarm system

_ Smoke and fire alarm system

_ Garage door controllers

_ Car door controllers

_ Car alarm system

_ Security system

_ Cordless telephones

_ Other remote control systems


The 212 decoders are a series of CMOS LSIs for remote control system

applications. They are paired with Holtek_s 212 series of encoders. For proper

operation, a pair of encoder/decoder with the same number of addresses and data

format should be chosen.

Appendix

Page 58

The decoders receive serial addresses and data from a programmed 212 series of

encoders that are transmitted by a carrier using an RF or an IR transmission

medium. They compare the serial input data three times continuously with their

local addresses. If no error or unmatched codes are found, the input data codes are

decoded and then transferred to the output pins. The VT pin also goes high to

indicate a valid transmission. The 212 series of decoders are capable of decoding

informations that consist of N bits of address and 12_N bits of data. Of this series,

the HT12D is arranged to provide 8 address bits and 4 data bits, and HT12F is used

to decode 12 bits of address information.

Operation:

The 212 series of decoders provides various combinations of addresses and data

pins in different packages so as to pair with the 212 series of encoders. The

decoders receive data that are transmitted by an encoder and interpret the first N

bits of code period as addresses and the last 12_N bits as data, where N is the

address code number. A signal on the DIN pin activates the oscillator which in turn

decodes the incoming address and data. The decoders will then check the received

address three times continuously. If the received address codes all match the

contents of the decoder_s local address, the 12_N bits of data are decoded to

activate the output pins and the VT pin is set high to indicate a valid transmission.

This will last unless the address code is incorrect or no signal is received. The

output of the VT pin is high only when the transmission is valid. Otherwise it is

always low.

Appendix

Page 59

PIC 16F877A Microcontroller

Introduction:

PIC is a family of modified Harvard architecture microcontrollers made by

Microchip Technology, derived from the PIC1650 originally developed by

General Instrument's Microelectronics Division. The name PIC initially

referred to "Peripheral Interface Controller".

Operating Frequency DC – 20 MHz

Resets (and Delays) POR, BOR

(PWRT, OST)

Flash Program Memory

(14-bit words) 8K

Data Memory (bytes) 368

EEPROM Data Memory (bytes) 256

Interrupts 15

I/O Ports Ports A, B, C, D, E

Timers 3

Capture/Compare/PWM modules 2

Serial Communications MSSP, USART

Parallel Communications PSP

10-bit Analog-to-Digital Module 8 input channels

Analog Comparators 2

Instruction Set 35 Instructions

Appendix

Page 60

Packages

40-pin PDIP

44-pin PLCC

44-pin TQFP

44-pin QFN

Table 9.4: PIC 16F877A Features

Special Microcontroller Features:

100,000 erase/write cycle Enhanced Flash program memory typical

1,000,000 erase/write cycle Data EEPROM memory typical

Data EEPROM Retention > 40 years

Self-reprogrammable under software control

In-Circuit Serial Programming™ (ICSP™) via two pins

Single-supply 5V In-Circuit Serial Programming

Watchdog Timer (WDT) with its own on-chip RC oscillator for reliable

operation

Programmable code protection

Power saving Sleep mode

Selectable oscillator options

In-Circuit Debug (ICD) via two pins

Appendix

Page 61

RFID Reader RKI-1512

Fig 9.8: RFID Reader RKI-1512

Description:

The ROBOKITS RFID reader is a standalone module with RFID reader and

antenna. Its very small (32mmx32mm) in size and easy to integrate with any

hardware design. It supports 125KHz RFID tags and has DIP 0.1” pins too.

Onboard antenna and hard plastic cover makes device small and sturdy. The

module works on UART protocol which allows user to integrate it with any PC

or Microcontroller based design. It also supports Weigand protocol.

Appendix

Page 62

Technical Parameters:

• Voltage: DC 5V

• Current: <50ma

• Operating Frequency: 125 KHz

• Reading Distance: 5 CM, 10 CM (Maximum, only for special tags)

• Dimensions 32mm X 32mm X 8mm

Pin Outs:

Fig 9.9: RKI-1512 Pin Diagram

1 VCC- 5V

2 GND- GND

Appendix

Page 63

3 BEEP- BEEP AND LED

4 NC- NOT CONNECTED

5 NC- NOT CONNECTED

6 SEL- HIGH IS UART,LOW IS WEIGAND

7 TX- UART TX

8 D1- WEIGAND DATA 1 (Optional)

9 D0- WEIGAND DATA 0 (Optional)

Application Circuit:

Fig 9.10: RKI-1512 Connections

Note: Connect GND & TX to UART port of MCU or PC.

Appendix

Page 64

L298 Motor Driver

Introduction:

The L298 is an integrated monolithic circuit in a 15- lead Multiwatt and

PowerSO20 packages. It is a high voltage, high current dual full-bridge

driver designed to accept standard TTL logic levels and drive inductive

loads such as relays, solenoids, DC and stepping motors. Two enable inputs

are provided to enable or disable the device independently of the input

signals. The emitters of the lower transistors of each bridge are connected to

gether and the corresponding external terminal can be used for the

connection of an external sensing resistor. An additional supply input is

provided so that the logic works at a lower voltage.

Fig 9.10: Pin diagram of L298

Appendix

Page 65

Table 9.5: L298 Pin Functions

Fig 9.11: Circuit Diagram For L298 Motor Driver

Appendix

Page 66

Above is the circuit shown of Motor driver based on L298 which is

configured for Bidirectional Motion of motors. The operation is as follows:

Table 9.6: L298 Operation

Advantages of L298:

Operating supply voltage up to 46 v

Total dc current up to 4 A

Low saturation voltage

Over temperature protection

Appendix

Page 67

LM-7805/12

Features:

• Output Current up to 1A

• Output Voltages of 5/12V

• Thermal Overload Protection

• Short Circuit Protection

• Output Transistor Safe Operating Area Protection

The KA78XX/KA78XXA series of three-terminal positive regulator 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.

Fig 9.12: LM7805/12 Packages

Appendix

Page 68

We have used TO-220 type 7805 and 7812 in our circuit.

Table 9.7: LM7805 Electrical Characteristics

Appendix

Page 69

Table 9.8: LM7812 Electrical Characteristics

References

www.robokits.co.in

www.alldatasheet.com

http://www.robokits.co.in/

http://www.alldatasheet.com/

rfid based industrial inventory control system

Documents

project work

project model

control engineering

major project report

vishal vaidya project

control room

conveyor belt

department of instrumentation