A PROJECT REPORT

ON
SPEED CONTROL OF BLDC MOTOR APPLICATIONS

SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENT FOR

THE DEGREE OF
BACHELOR OF TECHNNOLOGY
IN
ELECTRICAL ENGINEERING
SUBMITTED BY
STUDENT NAME ROLL NO.
STUDENT NAME ROLL NO.
STUDENT NAME ROLL NO.
STUDENT NAME ROLL NO.

UNDER THE SUPERVISION OF

PROFF NAME
ASSISTANT PROFESSOR
(ELECTRICAL ENGINEERING)

DEPARTMENT OF ELECTRICAL ENGINEERING

UNITED COLLEGE OF ENGINEERING & RESEARCH ALLAHABAD

AFFILIATED TO DR. APJ ABDUL KALAM TECHNICAL UNIVERSITY

i
 DECLARATION

We the students of B.TECH ELECTRICAL ENGINEERING hereby declare that the

work detail in the project entitled “SPEED CONTROL OF BLDC MOTOR
APPLICATIONS” submitted to Department of Electrical Engineering, “United College
of Engineering and Research Naini Allahabad”, under the “DR. APJ ABDUL KALAM
TECHNICAL UNIVERSITY” for the award bachelor of technology degree is our original
work, we have neither plagiarized nor submitted of any other degree .in case this
undertaking is found incorrect, we accept that our degree may be unconditionally
withdrawn.

DATE:
VENUE: ALLAHABAD
STUDENT NAME(ROLL NO)

ii
 CERTIFICATE

Certified that work presented in this report entitled “SPEED CONTROL OF

BLDC MOTOR APPLICATION” for the award bachelor of technology from
“DR. APJ ABDUL KALAM TECHNICAL UNIVERSITY,
LUCKNOW”, embodies results of original work, and the studies are carried out
by us and the content of the thesis do not from the basis for award of any other
degree to the candidate or to anybody else from this or any other university/
institutions.

STUDENT NAME (ROLL NO)

NAME NAME
(PROJECT GUIDE) (HEAD OF DEPARTMENT)

iii
 ACKNOWLEDGMENT

We have taken efforts in this project. However, it would not have been possible without the
kind support and help of many individuals and organizations. I would like to extend my sincere
thanks to all of them.

I am highly indebted to “Asst. Professor NAME, Department of Electrical engineering,

United College of Engineering and Research Naini Allahabad”, for their guidance and
constant supervision as well as for providing necessary information regarding the project & also
for their support in the project.

We also take the opportunity to acknowledge the contribution of NAME, HEAD OF

Department of mechanical engineering, United College of Engineering and Research Naini
Allahabad”.

I would like to express my gratitude towards my parents & classmates for their kind
cooperation and encouragement which help me in completion of this project.

My thanks and appreciations also go to those people who have willingly helped me out with
their abilities for developing the project.

NAME(ROLL NO)
NAME(ROLL NO)
NAME(ROLL NO)

(Department of Electrical Engineering)

iv
 ABSTRACT

The hardware project is designed to control the speed of a BLDC motor using closed
loop control technique. BLDC motor has various application used industries like in
drilling, lathes, spinning, electric bikes etc. The speed control of the DC motors is
very essential. This proposed system provides a very precise and effective speed
control system. The user can enter the desired speed and the motor will run at that
exact speed. The report is divided into parts for explaining the step by step
development of the project. The first part introduces the idea behind the project
and the underlying information of the technologies used. Next chapter is dedicated
for information on the equipment’s used and how they were accommodated in
the project circuitry. The working of the project with the programming code are
explained after that. Lastly, the merits, de-merits and future prospects of the project
are given.

v
 CONTENTS

Contents
CONTENTS ..............................................................................................................................................viii

LIST OF FIGURES ............................................................................. Error! Bookmark not defined.

CHAPTER 1 INTRODUCTION .......................................................................................................................... 1
INTRODUCTION ........................................................................................................................................ 2
CHAPTER 2 .................................................................................................................................................. 12
Pin Descriptions ...................................................................................................................................... 17
ATmega 16.............................................................................................................................................. 18
Fig2.2 Pin configuration of ATmega 16.............................................................................................. 18
5. PC6/RESET ...................................................................................................................................... 19
6. Port D (PD7:0) ................................................................................................................................. 19
7. AVCC ............................................................................................................................................... 20
8. AREF ............................................................................................................................................... 20
9.ADC7:6................................................................................................................................................. 20
2.1.3 LIQIUD CRYSTAL DISPLAY(LCD): ................................................................................................... 21
Fig 2.3.LCD............................................................................................................................................... 21
2.1.3.1 Features : ................................................................................................................................... 22
2.1.4 MOTOR DRIVER IC L293D: .......................................................................................................... 22
2.2PCB (PRINTED CIRCUIT BOARD) DESIGNING: ..................................................................................... 26
2.2.1 LAYOUT OF THE PROJECT PCB ...................................................................................................... 28
2.2.1.A Solder side of the PCB ........................................................................................................... 28
2.2.1.b Component side of the PCB:...................................................................................................... 28
2.2.2PCB-DESIGNING.............................................................................................................................. 29
2.2.2.1PROCESSING ................................................................................................................................ 30
2.2.2.2CLEANING .................................................................................................................................... 31
2.2.2.3 ETCHING ................................................................................................................................. 31
2.2.2.4 DRILLING................................................................................................................................. 31
2.2.2.5 SOLDERING ............................................................................................................................. 32
2.2.2.6 MASKING ................................................................................................................................ 32
2.2.3 PCB LAYOUT ............................................................................................................................ 32
Express P.C.B........................................................................................................................................... 33

viii
CHAPTER 3 .................................................................................................................................................. 34
CHAPTER 5 .................................................................................................................................................. 52
5 ADVANTAGES & DISADVANTAGE .................................................................................................... 53
5.1ADVANTAGES: ................................................................................................................................... 53
5.2DISADVANTAGES: .............................................................................................................................. 54
CHAPTER 6 .............................................................................................................................................. 55
6.1 APPLICATIONS ............................................................................................................................ 56
REFERNCES: ............................................................................................................................................ 57

ix
 CHAPTER 1
INTRODUCTION

1
 INTRODUCTION

1.1 Introduction

Permanent-magnet excited brushless DC motors are becoming increasingly

attractive in a large number of applications due to performance advantages such as
reduced size and cost, reduced torque ripples, increased torque-current ratio, low
noises, high efficiency, reduced maintenance and good control characteristics over
a wide range in torque–speed plan. In general, Brushless DC motors such as fans
are smaller in size and weight than AC fans using shaded pole or Universal motors.
Since these motors have the ability to work with the available low voltage sources
such as 24-V or 12-V DC motor fans convenient for use in electronic
equipment, computers, mobile equipment, vehicles, and spindle drives for disk
memory, because of its high reliability, efficiency, and ability to reverse rapidly.
Brushless dc motors in the fractional horsepower range have been used in various
types of actuators in advanced aircraft and satellite systems . Most
popular brushless DC motors are mainly three phases which are controlled and
driven by full bridge transistor circuits. Together with applying permanent magnet
excitation, it is necessary to obtain additional torque components. These components
can be obtained due to a difference in magnetic presence in both quadrature and
direct axis; therefore, reluctance torque is developed and torque null regions are
reduced significantly. In this paper, a brushless DC motor with distributed winding
and a special form of PM-rotor with special stator periphery are described. Which
develop a speed control
system for a BLDC motor by closed loop
control technique. The proposed system uses a microcontroller of the 8051 family
2
and a rectified-power supply. A set of IR transmitter and photodiode are connected
to the microcontroller for counting the number of rotations per minute of the DC
motor as a speed sensor. Optocoupler is connected to trigger the MOSFET for
driving the BLDC motor which is duly interfaced to the microcontroller. A matrix
keypad is interfaced to the microcontroller for controlling the speed of the motor.
The speed control of the BLDC motor is archived by varying the duty cycles (PWM
Pulses) from the microcontroller according to the program. The microcontroller
receives the percentage of duty cycles from the keypad and delivers the desired
output to switch the motor driver so as to control the speed of the BLDC motor. The
speed sensed by the IR sensor is given to the microcontroller to display it on the
LCD display.

BLDC MOTOR

BLDC motors are similar to synchronous motors in working. This means the
magnetic field generated by the stator and the magnetic field generated by the rotor
rotates at the same frequency. BLDC motors do not experience the “slip” that is
normally seen in induction motors. BLDC motors come in single-phase, 2-phase and
3-phase configurations. Corresponding to its type, the stator has the same number of
windings. Out of these, 3-phase motors are the most popular and widely used.
STATOR

The stator of BLDC motor is made out of laminated steel stacked up to carry the
windings. Windings in a stator can be arranged in two patterns; i.e. a star pattern (Y)
or delta pattern (∆). The major difference between the two patterns is that the Y
pattern gives high torque at low RPM and the ∆ pattern gives low torque at low
RPM. This is because in the ∆ configuration, half of the voltage is applied across the

3
winding that is not driven, thus increasing losses and, in turn, efficiency and torque.
Steel laminations in the stator can be slotted or slotless as shown in figure 1(a) and
1(b).

(a): Slotted motor (b): Slotless motor

Figure 1.1: Slotted and slot less BLDC motor

A slotless core has lower inductance, thus it can run at very high speeds. Because of
the absence of teeth in the lamination stack, requirements for the cogging torque also
go down, thus making them an ideal fit for low speeds too (when permanent magnets
on rotor and tooth on the stator align with each other, because of the interaction
between the two, an undesirable cogging torque develops and causes ripples in
speed). The main disadvantage of a slotless core is higher cost because it requires
more winding to compensate for the larger air gap. Proper selection of the laminated
steel and windings for the construction of stator are crucial to motor performance.

4
ROTOR
The rotor of a typical BLDC motor is made out of permanent magnets. Depending
upon the application requirements, the number of poles in the rotor may vary.
Increasing the number of poles gives better torque but at the cost of reducing the
maximum possible speed. Another rotor parameter that impacts the maximum
torque is the material used for the construction of permanent magnet; the higher
the flux density of the material, the higher the torque. There are mainly 2 types of
rotor construction: interior and exterior.

(a): Exterior rotor (b): Interior rotor

Figure 1.2: Interior and exterior rotor

5
In the exterior rotor design, the windings are located in the core of the motor. The
rotor magnets surround the stator windings as shown in figure 2(a). The rotor
magnets act as an insulator, thereby reducing the rate of heat dissipation from the
motor. Due to the location of stator windings, outer rotor designs typically operate
at lower duty cycles or at a lower current. The primary advantage of an external
rotor BLDC motor is relatively low cogging torque.
In an interior rotor design, the stator windings surround the rotor and are affixed to
the motors housing as shown in figure 2(b). The primary advantage of interior rotor
design is better heat dissipation. A motor‟s ability to dissipate heat directly impacts
its ability to produce torque. Another major advantage of interior rotor design is
lower rotor inertia. For this reason, the overwhelming majority of BLDC motors use
an interior rotor design.

1.2 WORKING
The underlying principle for the working of a BLDC motor is the same as for a
brushed DC motor; i.e., internal shaft position feedback. In case of a brushed DC
motor, feedback is implemented using a mechanical commutator and brushes.
Within a BLDC motor, it is achieved using multiple feedback sensors. The most
commonly used sensors are hall sensors and optical encoders. In a commutation
system two of the three electrical windings are energized at a time as shown in
figure 3.

6
 Figure 3(a): Phase 1 Figure 3(b): Phase 2

Figure 3(c): Phase 3 Figure 3(d): Phase 4

Figure 3(e): Phase 5 Figure 3(f): Phase 6

Figure 1.3: BLDC motor working Page | 5
In figure 3(a), the GREEN winding is energized as the NORTH pole and the BLUE
winding is energized as the SOUTH pole. Because of this excitation, the SOUTH
pole of the rotor aligns with the GREEN winding and the NORTH pole aligns with
the RED winding. In order to move the rotor, the “RED” and “BLUE” windings are
energized in the direction shown in figure 3(b). This causes the RED winding to
become the NORTH pole and the BLUE winding to become the SOUTH pole. This
shifting of the magnetic field in the stator produces torque because of the
development of repulsion (Red winding – NORTH-NORTH alignment) and
attraction forces (BLUE winding – NORTH-SOUTH alignment), which moves the
rotor in the clockwise direction. This torque is at its maximum when the rotor starts
to move, but it reduces as the two fields align each other. Thus, to preserve the torque
or to build up the rotation, the magnetic field generated by stator should keep
switching. To catch up with the field generated by the stator, the rotor will keep
rotating. Since the magnetic field of the stator and rotor both rotate at the same
frequency, they come under the category of synchronous motor.
This switching of the stator to build up the rotation is known as commutation. For
3- phase windings, there are 6 steps in the commutation; i.e., 6 unique combinations
in which motor windings will be energized.
 CHAPTER 2
EQUIPMENT & PCB
DESGINING
 2.1 EQUIPMENTS:

The different major equipment’s used in system are enlisted below:

a) Bluetooth
b) Microcontroller (ATEMEGA 16)
c) LCD
d) Gas sensor
e) Power supply
f) Temperature sensor
g) Motor driver IC L293D

2.1.1 Bluetooth Module HC-05:

Bluetooth is a wireless technology standard for exchanging data over short

distances (using short-wavelength UHF radio waves in the ISM band from 2.4 to
2.485 GHz[4]) from fixed and mobile devices, and building personal area
networks (PANs). Invented by telecom vendor Ericsson in 1994,[5] it was originally
conceived as a wireless alternative to RS-232 data cables. It can connect several
devices, overcoming problems of synchronization.
Bluetooth is managed by the Bluetooth Special Interest Group (SIG), which has more
than 25,000 member companies in the areas of telecommunication, computing,
networking, and consumer electronics.[6] The IEEE standardized Bluetooth as IEEE
802.15.1, but no longer maintains the standard. The Bluetooth SIG oversees
development of the specification, manages the qualification program, and protects the
trademarks.[7] A manufacturer must make a device meet Bluetooth SIG standards to
market it as a Bluetooth device.[8] A network of patents applies to the technology,
which are licensed to individual qualifying devices.
Overview

Fig 2.1 Bluetooth module

HC-05 module is an easy to use Bluetooth SPP (Serial Port Protocol) module, designed
for transparent wireless serial connection setup.
Serial port Bluetooth module is fully qualified Bluetooth V2.0+EDR (Enhanced Data
Rate) 3Mbps Modulation with complete 2.4GHz radio transceiver and baseband. It
uses CSR Bluecore 04-External single chip Bluetooth system with CMOS technology
and with AFH(Adaptive Frequency Hopping Feature). It has the footprint as small as
12.7mmx27mm. Hope it will simplify your overall design/development cycle.
Specifications
Hardware Features
 Typical -80dBm sensitivity
 Up to +4dBm RF transmit power
 Low Power 1.8V Operation ,1.8 to 3.6V I/O
 PIO control
 UART interface with programmable baud rate
 With integrated antenna
  With edge connector
Software Features
 Default Baud rate: 38400, Data bits: 8, Stop bit: 1, Parity: No parity, Data
control: has.
Supported baud rate: 9600, 19200, 38400, 57600, 115200, 230400, and 460800.
 Given a rising pulse in PIO0, device will be disconnected.
 Status instruction port PIO1: low-disconnected, high-connected;
 PIO10 and PIO11 can be connected to red and blue led separately. When master
and slave are paired, red and blue led blinks 1time/2s in interval, while
disconnected only blue led blinks 2times/s.
 Auto-connect to the last device on power as default.
 Permit pairing device to connect as default.
 Auto-pairing PINCODE:”0000” as default
 Auto-reconnect in 30 min when disconnected as a result of beyond the range of
connection.

2.1.2ATMEGA 16:

A microcontroller (sometimes abbreviated µC, uC or MCU) is a small

computer on a single integrated circuit containing a processor core, memory, and

programmable input/output peripherals. Microcontrollers are designed for

embedded applications, in contrast to the microprocessors used in personal

computers or other general purpose applications. . By reducing the size and cost

compared to a design that uses a separate microprocessor, memory, and

input/output devices, microcontrollers make it economical to digitally control even

more devices and processes

The Atmel®AVR® core combines a rich instruction set with 32 general

purpose working registers. All the 32 registers are directly connected to the

Arithmetic Logic Unit (ALU), allowing two independent registers to be accessed

in one single instruction executed in one clock cycle. The resulting architecture is

more code efficient while achieving throughputs up to ten times faster than

conventional CISC microcontrollers.

The ATmega8 provides the following features: 8 Kbytes of In-System

Programmable Flash with Read-While-Write capabilities, 512 bytes of EEPROM,

1 Kbyte of SRAM, 23 general purpose I/O lines, 32 general purpose working

registers, three flexible Timer/Counters with compare modes, internal and external

interrupts, a serial programmable USART, a byte oriented Two wire Serial

Interface, a 6-channel ADC (eight channels in TQFP and QFN/MLF packages)

with 10-bit accuracy, a programmable Watchdog Timer with Internal Oscillator, an

SPI serial port, and five software selectable power saving modes. The Idle mode

stops the CPU while allowing the SRAM, Timer/Counters, SPI port, and interrupt

system to continue functioning. The Powerdown mode saves the register contents

but freezes the Oscillator.

Pin Descriptions
1. VCC

Digital supply voltage.

2 GND

Ground.

3 Port B (PB7:0) XTAL1/XTAL2/TOSC1/TOSC2

Port B is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for

each bit). The Port B output buffers have symmetrical drive characteristics with

both high sink and source capability. As inputs, Port B pins that are externally

pulled low will source current if the pull-up resistors are activated. The Port B pins

are tri-stated when a reset condition becomes active, even if the clock is not

running
 ATmega 16

Fig2.2 Pin configuration of ATmega 16

4. Port C (PC5:0)

Port C is a 7-bit bi-directional I/O port with internal pull-up resistors (selected for

each bit). The PC5..0 output buffers have symmetrical drive characteristics with

both high sink and source capability. As inputs, Port C pins that are externally

pulled low will source current if the pull-up resistors are activated. The Port C pins

are tri-stated when a reset condition becomes active, even if the clock is not

running.

5. PC6/RESET

If the RSTDISBL Fuse is programmed, PC6 is used as an I/O pin. Note that the

electrical characteristics of PC6 differ from those of the other pins of Port C.

If the RSTDISBL Fuse is unprogrammed, PC6 is used as a Reset input. A

low level on this pin for longer than the minimum pulse length will generate a

Reset.

6. Port D (PD7:0)

Port D is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for

each bit). The Port D output buffers have symmetrical drive characteristics with

both high sink and source capability. As inputs, Port D pins that are externally

pulled low will source current if the pull-up resistors are activated. The Port D pins
are tri-stated when a reset condition becomes active, even if the clock is not

running.

7. AVCC

AVCC is the supply voltage pin for the A/D Converter, PC3:0, and ADC7:6. It

should be externally connected to VCC, even if the ADC is not used. If the ADC is

used, it should be connected to VCC through a low-pass filter.

8. AREF

AREF is the analog reference pin for the A/D Converter.

9.ADC7:6

In the TQFP and QFN/MLF package, ADC7:6 serve as analog inputs to the A/D

converter. These pins are powered from the analog supply and serve as 10-bit

ADC channels.
2.1.3 LIQIUD CRYSTAL DISPLAY(LCD):
A liquid crystal display (LCD) is a flat panel display, electronic visual display,

or video display that uses the light modulat. LCDs do not emit light directly.LCDs

are used in a wide range of applications ,including computer monitors, television,

instrument panels, aircraft cockpit displays, signage, etc. They are common in

consumer devices such as video players, gaming Fig3 LCD devices, clocks,

watches, calculators, and telephones.

This LCD's typically have 14 data pins and 2 for the LED backlight. Character

LCDs use a standard 14-pin interface and those with backlights have 16 pins.

There is also be a single backlight pin, with the other connection via Ground or

VCC pin. The two backlight pins may precede the pin 1. The nominal backlight

voltage is around 4.2V at 25˚C using a VDD 5V capable model.

Fig 2.3.LCD
2.1.3.1 Features :
a) 5 ´ 8 and 5 ´ 10 dot matrix possible
b)Low power operation support:
2.7 to 5.5V
c) Wide range of liquid crystal display driver power
3.0 to 11V
d) 80 ´ 8-bit display RAM (80 characters max.)

2.1.4 MOTOR DRIVER IC L293D:

L293D is a dual H-bridge motor driver integrated circuit (IC). Motor drivers act as

current amplifiers since they take a low-current control signal and provide a higher-

current signal. This higher current signal is used to drive the motors.

L293D contains two inbuilt H-bridge driver circuits. In its common mode of

operation, two DC motors can be driven simultaneously, both in forward and

reverse direction. The motor operations of two motors can be controlled by input

logic at pins 2 & 7 and 10 & 15. Input logic 00 or 11 will stop the corresponding

motor. Logic 01 and 10 will rotate it in clockwise and anticlockwise directions,

respectively.

Enable pins 1 and 9 (corresponding to the two motors) must be high for motors to

start operating. When an enable input is high, the associated driver gets enabled. As

a result, the outputs become active and work in phase with their inputs. Similarly,

when the enable input is low, that driver is disabled, and their outputs are off and in

22
the high-impedance state.

Working of L293D

There are 4 input pins for l293d, pin 2,7 on the left and pin 15 ,10 on the right as

23
shown on the pin diagram. Left input pins will regulate the rotation of motor

connected across left side and right input for motor on the right hand side. The

motors are rotated on the basis of the inputs provided across the input pins as

LOGIC 0 or LOGIC 1.

In simple you need to provide Logic 0 or 1 across the input pins for rotating the

motor.

L293D Logic Table

Let’s consider a Motor connected on left side output pins (pin 3,6). For rotating the

motor in clockwise direction the input pins has to be provided with Logic 1 and

Logic 0.

• Pin 2 = Logic 1 and Pin 7 = Logic 0 | Clockwise Direction

• Pin 2 = Logic 0 and Pin 7 = Logic 1 | Anticlockwise Direction

• Pin 2 = Logic 0 and Pin 7 = Logic 0 | Idle [No rotation] [Hi-Impedance state]

• Pin 2 = Logic 1 and Pin 7 = Logic 1 | Idle [No rotation]

Voltage Specification

VCC is the voltage that it needs for its own internal operation 5v; L293D will not

use this voltage for driving the motor. For driving the motors it has a separate

provision to provide motor supply VSS (V supply). L293d will use this to drive the

motor. It means if you want to operate a motor at 9V then you need to provide a

Supply of 9V across VSS Motor supply.

The maximum voltage for VSS motor supply is 36V. It can supply a max current
24
of 600mA per channel. Since it can drive motors Up to 36v hence you can drive

pretty big motors with this l293d.

VCC pin 16 is the voltage for its own internal Operation. The maximum voltage

ranges from 5v and up to 36v.

2.1.5 GAS SENSOR :MQ6

Fig:2.4 Gas sensor

Fig 2.5 Internal circuit

General Description
25
The LPG Gas sensor Module for use in Home or Factory to warn of fatal LPG build-
ups. The module uses MQ-6 sensor to sense LPG leak. It's ready to run circuit with no
additional circuitry. Corresponding to the concentration of the gas it provides both
analog and digital output. The output interface from the sensor module can be
connected to ADC of a microcontroller for wider range of sensor reading. The
calibration is quite easy using on-board potentiometer.

Features
Uses the MQ-6 LPG Gas Sensor
Easy SIP interface
Compatible with most microcontrollers
Onboard Status and Power LED
Onboard potentiometer for threshold setting

This is a simple-to-use liquefied petroleum gas (LPG) sensor, suitable for sensing LPG
(composed of mostly propane and butane) concentrations in the air. The MQ-6 can
detect gas concentrations anywhere from 200 to 10000ppm.
This sensor has a high sensitivity and fast response time. The sensor’s output is an
analog resistance. The drive circuit is very simple; all you need to do is power the
heater coil with 5V, add a load resistance, and connect the output to an ADC.

2.2PCB (PRINTED CIRCUIT BOARD) DESIGNING:

A printed circuit board, or PCB, is used to mechanically support and electrically

connect electronic components using conductive pathways, tracks or traces etched

from copper sheets laminated onto a non-conductive substrate. It is also referred to

as printed wiring board (PWB) or etched wiring board. A PCB populated with

electronic components is a printed circuit assembly (PCA), also known as a printed

circuit board assembly (PCBA)

26
PCBs are inexpensive, and can be highly reliable. They require much more layout

effort and higher initial cost than either wire-wrapped or point-to-point constructed

circuits, but are much cheaper and faster for high-volume production. Much of the

electronics industry's PCB design, assembly, and quality control needs are set by

standards.

27
2.2.1 LAYOUT OF THE PROJECT PCB

2.2.1.A Solder side of the PCB

Fig2.6: PCB Layout of soldering side

2.2.1.b Component side of the PCB:

Fig 2.7:PCB Layout of Component side

28
2.2.2PCB-DESIGNING

PCB Designing includes the following steps:-

PROCESSING

CLEANSING

PRINTING

ETCHING

DRILLING

SOLDERING

MASKING

Fig2.8 : PCB Designing process

29
2.2.2.1PROCESSING

The layout of a PCB has to incorporate all the information on the board before one

can go on to the artwork preparation. This means that a concept that clearly defines

all the details of the circuit and partly also of the final equipment, is a prerequisite

before the actual layout can start. The detail circuit diagram is very important for

the layout designer and he must also be familiar with the design concept and with

the philosophy behind the equipment. The General Considerations are-

a-) Layout scale:- Depending on the accuracy required, artwork should be

produced at a 1:1 or 2:1 or even 4:1 scale. The layout is best prepared on the same

scale as the artwork. This prevents all the problems which might be caused by

redrawing of layout to the artwork scale.

b-) Grid system or Graph Paper: - It is commonly accepted practice to use

these for designing.

c-) Board types:-There are two side of a PCB board – Component side &
Solder side. Depending on these board are classified as-

Single-sided Boards: - These are used where costs have to be kept at a

minimum & a particular Circuit can be accommodated on such board. To

jump over conductor tracks, components have to be utilized. If this is not

30
 feasible, jumper wires are used. (Jumper wires should be less otherwise

double-sided PCB should be considered.

Double-sided Boards: - These are made with or without plated through

holes. Plated through holes are fairly expensive.

2.2.2.2CLEANING
The cleaning of the copper surface prior to resist application is an essential step for

any type of PCB process using etches or plating resist.After scrubbing with the

abrasive, a water rinse will remove most of the remaining slurry.

Scrubbing Pumice/ Acid Slurry

Water Rinse Tap Water

Wet Brushing Tap Water

Acid dip Hydrochloric Acid-HCl

Final Rinse De-ionized Water

Drying Oven or Blowing of air.

Fig 2.9: PCB cleaning process

 2.2.2.3 ETCHING

It is of utmost importance to choose a suitable Etchant Systems. There are many

factors to be considered:-

 Etching speed

 Copper solving capacity

 Etchant price

 Pollution character

We have uses FeCl3 (Conc. 120 g/litre 0.1 M) for etching.

2.2.2.4 DRILLING

The importance of hole drilling into PCB’s has further gone with electronic

component miniaturization and its need for smaller holes diameters (diameters less

than half the board thickness) and higher package density.

The following hole diameter tolerances have been generally accepted wherever no

other specifications are mentioned.

Hole Diameter (D) <= 1mm + / - 0.05 mm

Hole Diameter (D) > 3 mm + / – 0.1 mm

2.2.2.5 SOLDERING

Flux should be removed after Soldering. It is done through washing by 0.5—1 %

HCl followed by Neutralization in dilute alkali to remove corrosive flux.Non-

corrosive is removed by Iso-Propanal.

2.2.2.6 MASKING

It is done for the protection of conductor track from Oxidation.

2.2.3 PCB LAYOUT

A PCB layout is required to place components on the PCB so that the component

area can be minimized and the components can be placed in an efficient manner.

The components can be placed in two ways, either manually or by software. The

manual procedure is quiet cumbersome and is very inefficient. The other method is

by the use of computer software. This method is advantageous as it saves time and

valuable copper area. There are various software’s available for this purpose like-

 Express PCB

 Pad2pad

 Protel PCB

 PCB design e.t.c.

Many of them are loaded with auto routing and auto placement facility. The

software that we have used here is EXPRESS PCB. This software has a good

interface, easy editing options and a wide range of components.

Express P.C.B.

Express PCB is a very easy to use Windows application for laying out

printed circuit boards. There are two parts to Express PCB, Express SCH for

drawing schematics and Express PCB for designing circuit boards. We downloaded

the software from the website www.expresspcb.com.

There are lots of functions available in the software. This software is free of

cost and it is very easy to use. The different layers of the PCB can be viewed by

just a click of a button on the interface. And we easily get its print on paper which

is utilized for further processing. We can design single sided PCB as well as

Double Sided PCB with this Software.

 CHAPTER 3
COMPONENT LIST
 3.COMPONENT PART LIST

The list of component used is enlisted below :

COMPONENT MODEL QUANTITY

BLDC MOTOR FAN 1
Microcontroller ATMEGA 16 1
TEMP SENSOR LM35 1
GAS SENSOR MQ6 4
LCD HD44780U 1
LED 6
Variable resistance 1
Voltage Regulator LM 7805 1
Diode IN 4007 2
Resistance 1Kohm 6
Resistance 10Kohm 1
Crystal oscillator(10 1
MHz)
Ceramic capacitor 104/AEC 1
Ceramic capacitor 33/AEC 2
Connector 9
Connecting wires
 CHAPTER 4

WORKING OPERATION &

PROGRAMMING CODE
4 WORKING OPERATION & PROGRAMMING CODE

This chapter deals with working of ―application and speed control of BLDC

motor. This chapter also introduces programming used in microcontroller.

4.1 WORKING:

One of the many application of the bldc motor is used as exhaust fan . in this paper
we use two sensors to show the application of exhaust fan.
Temperature sensor LM35 is used to sense the temperature and send a signal to the
microcontroller ATMEGA16 which has a motor driver ic L293D for controlling the
speed of motor. we set 40° temperature for normal opeartion.

We use a gas sensor for detecting gas leakage and increase the speed of fan to
remove the leakage gas as soon as possible.
In normal mode the fan is in sleeping mode whenever the sensor gives signal to the
microcontroller it rotates at its full speed.
Fig 4.1.BLOCK DIAGRAM
4.2 CIRCUIT DIAGRAM :

Fig4.2. circuit diagram

 4.3 PROGRAMMING CODE:

ATMEGA 168 operate for both analog as well as digital signal.programming

of this microcontroller is done in compiler AVR STUDIO which is open

source free compiler.Programing code is written below:

#define F_CPU 2000000UL

#include<avr/io.h>
#include <util/delay.h>
#include<stdio.h>
#include<avr\interrupt.h>

#define Motor12 PORTC // In my case PORTC is the PORT from which I set the RS , R/W and
En

#defineEn1 PORTC7 // Enable signal

#defineIN11 PORTC6 // Read/Write signal
#defineIN12 PORTC5 // Register Select signal

unsigned char y=250;

int cor,l,m,n,a,b, j, k, f, g, h, q;

#define LCD_DATA PORTB // In my case PORTB is the PORT from which I send data to my
LCD
#define Control_PORT PORTA // In my case PORTC is the PORT from which I set the RS ,
R/W and En
#define En PORTA7 // Enable signal
#define RW PORTA6 // Read/Write signal
#define RS PORTA5 // Register Select signal

void ADC_init(void);
unsigned int ADC_read(unsigned char);

void LCD_cmd(unsigned char cmd)

{
LCD_DATA=cmd;
Control_PORT =(0<<RS)|(0<<RW)|(1<<En); // RS and RW as LOW and EN as HIGH
_delay_ms(5);
Control_PORT =(0<<RS)|(0<<RW)|(0<<En); // RS, RW , LOW and EN as LOW
_delay_ms(5);return;
}
void LCD_write(unsigned char data)
{
LCD_DATA= data;
Control_PORT = (1<<RS)|(0<<RW)|(1<<En); // RW as LOW and RS, EN as HIGH
_delay_ms(5);
Control_PORT = (1<<RS)|(0<<RW)|(0<<En); // EN and RW as LOW and RS HIGH
_delay_ms(5); // delay to get things executed
return ;
}

void init_LCD()
{

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);

void LCD_write_string(unsigned char *str) //take address vaue of the string in pionter *str
{
int i=0;
while(str[i]!='\0') // loop will go on till the NULL charaters is soon in string
{
LCD_write(str[i]); // sending data on CD byte by byte
i++;
}
return;
}

void usart_send(unsigned char data)

{

while(! (UCSRA & (1<<UDRE)));

UDR = data;
_delay_ms(5);
}

volatile uint8_t count;

int main(void)
{

DDRA=0Xf0;
DDRB=0XFF;
DDRD=0XFF;
DDRC=0XFF;

unsigned int value;

unsigned int data;

UCSRB = (( 1<<TXEN)| ( 1<<RXEN) ) ;

UCSRC = ( 1<<UCSZ1 ) | ( 1<<UCSZ0 ) | ( 1<<URSEL );
UBRRL = 0X0C; //9600 br

MCUCR=0x02;
GICR=(1<<INT0);

TCCR0|=(1<<CS02)|(1<<CS00); // Prescaler = FCPU/1024

TIMSK|=(1<<TOIE0); //Enable Overflow Interrupt Enable
TCNT0=0; //Initialize Counter
count=0; //Initialize our varriable
DDRC|=0x0F; //Port C[3,2,1,0] as out put

sei();//Enable Global Interrupts

k=0;

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);
_delay_ms(400);

LCD_write_string("RPM control of");

_delay_ms(20);
LCD_cmd(0XC0);
_delay_ms(5);
LCD_write_string(" BLDC motor");
_delay_ms(2000);

Motor12 =(0<<En1)|(0<<IN11)|(0<<IN12);

while(1)
{

//////////////////temp//////////

ADC_init(); // Initialization of ADC

// ch=0;

value=ADC_read(0);
data=(value/2);

//////////////////LCD Data

a=data;
b=a/10;
l=a%10;
m=b%10;
n=b/10;

n=n|0x30;
m=m|0x30;
l=l|0x30;

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);

LCD_write_string("Temp ");

_delay_ms(5);

LCD_write(m);
_delay_ms(5);

LCD_write(l);
_delay_ms(5);
LCD_write_string(" degC ");
_delay_ms(20);

usart_send('$');
_delay_ms(20);
usart_send('1');
_delay_ms(20);
usart_send(',');
_delay_ms(20);

usart_send('T');
_delay_ms(20);
usart_send('e');
_delay_ms(20);
usart_send('m');
_delay_ms(20);
usart_send('p');
_delay_ms(20);
usart_send(' ');
_delay_ms(20);
usart_send(m);
_delay_ms(20);
usart_send(l);
_delay_ms(20);
usart_send(' ');
_delay_ms(20);
usart_send('D');
_delay_ms(20);
usart_send('e');
_delay_ms(20);
usart_send('g');
_delay_ms(20);
usart_send('C');
_delay_ms(20);

usart_send('#');
_delay_ms(20);

if(m>0X33)

Motor12 =(1<<En1)|(1<<IN11)|(1<<IN12);

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);

LCD_write_string("Full speed");
_delay_ms(100);

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);
_delay_ms(40);

LCD_write_string("Temp out of range");

_delay_ms(100);

else

/////////////LPG//////////

if( PINA & (1<<1))

{
Motor12 =(1<<En1)|(1<<IN11)|(1<<IN12);

usart_send('$');
_delay_ms(20);
usart_send('2');
_delay_ms(20);
usart_send(',');
_delay_ms(20);

usart_send('L');
_delay_ms(20);
usart_send('P');
_delay_ms(20);
usart_send('G');
_delay_ms(20);
usart_send(' ');
_delay_ms(20);
usart_send('F');
_delay_ms(20);
usart_send('O');
_delay_ms(20);
usart_send('U');
_delay_ms(20);
usart_send('N');
_delay_ms(20);
usart_send('D');
_delay_ms(20);

usart_send('#');
_delay_ms(20);

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);
_delay_ms(400);

LCD_write_string("LPG GAS FOUND");

_delay_ms(100);

Motor12 =(1<<En1)|(1<<IN11)|(1<<IN12);

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);

LCD_write_string("Full speed");
_delay_ms(100);

}
else

{
usart_send('$');
_delay_ms(20);
usart_send('2');
_delay_ms(20);
usart_send(',');
_delay_ms(20);

usart_send('N');
_delay_ms(20);
usart_send('o');
_delay_ms(20);
usart_send(' ');
_delay_ms(20);

usart_send('L');
_delay_ms(20);
usart_send('P');
_delay_ms(20);
usart_send('G');
_delay_ms(20);
usart_send(' ');
_delay_ms(20);
usart_send('F');
_delay_ms(20);
usart_send('O');
_delay_ms(20);
usart_send('U');
_delay_ms(20);
usart_send('N');
_delay_ms(20);
usart_send('D');
_delay_ms(20);

usart_send('#');
_delay_ms(20);

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);
LCD_write_string("No LPG GAS FOUND");
_delay_ms(100);

Motor12 =(1<<En1)|(1<<IN11)|(1<<IN12);
_delay_ms(50);
Motor12 =(0<<En1)|(0<<IN11)|(0<<IN12);
_delay_ms(50);

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);

LCD_write_string("Normal speed");
_delay_ms(100);

//////////////////temp/////////
//////////////LPG/////////

return 0;

void ADC_init(void) // Initialization of ADC

{
ADMUX=0XC0; // AVcc with external capacitor at AREF
ADCSRA=(1<<ADEN)|(1<<ADPS2)|(1<<ADPS1)|(1<<ADPS0);
// Enable ADC and set Prescaler division factor as 128
}

unsigned int ADC_read(unsigned char ch)

{
ch= ch & 0b00000111; // channel must be b/w 0 to 7
ADMUX |= ch; // selecting channel

ADCSRA|=(1<<ADSC); // start conversion

while(!(ADCSRA & (1<<ADIF))); // waiting for ADIF, conversion complete
ADCSRA|=(1<<ADIF); // clearing of ADIF, it is done by writing 1 to it

return (ADC);
}

ISR(INT0_vect)
{
j=j+1;
}

ISR(TIMER0_OVF_vect)
{
//This is the interrupt service routine for TIMER0 OVERFLOW Interrupt.
//CPU automatically call this when TIMER0 overflows.

//Increment our variable

count++;
if(count==61)
{

k=k+1;

if(k>4)
{

// show speed

//j=j*6;

//j=j/4;
Motor12 =(0<<En1)|(0<<IN11)|(0<<IN12);

q=j/10;
f=j%10;
g=q%10;
h=q/10;

h=h|0x30;
g=g|0x30;
f=f|0x30;

LCD_cmd(0X38);
_delay_ms(5);
LCD_cmd(0X01);
_delay_ms(5);
LCD_cmd(0X0C);
_delay_ms(5);
LCD_cmd(0X80);
_delay_ms(5);

LCD_write_string("SP ");
_delay_ms(20);

LCD_write(h);
_delay_ms(5);

LCD_write(g);
_delay_ms(5);

LCD_write(f);
_delay_ms(5);

LCD_write(' ');
_delay_ms(5);

LCD_write('R');
_delay_ms(5);

LCD_write('P');
_delay_ms(5);

LCD_write('M');
_delay_ms(500);

usart_send('$');
_delay_ms(20);
usart_send('1');
_delay_ms(20);
usart_send(',');
_delay_ms(20);
usart_send(' ');
_delay_ms(20);
usart_send(' ');
_delay_ms(20);
usart_send(h);
_delay_ms(20);
usart_send(g);
_delay_ms(20);
usart_send(f);
_delay_ms(20);
usart_send(' ');
_delay_ms(20);
usart_send('R');
_delay_ms(20);
usart_send('P');
_delay_ms(20);
usart_send('M');
_delay_ms(20);
usart_send('#');
_delay_ms(20);

j=0;
k=0;

Motor12 =(0<<En1)|(0<<IN11)|(0<<IN12);
_delay_ms(500);

Motor12 =(0<<En1)|(0<<IN11)|(0<<IN12);
}

else
{

count=0;
}
}
 CHAPTER 5
ADVANTAGES &
DISADVANTAGES
5ADVANTAGES & DISADVANTAGE

This project is made with best of capabilities and dedication. Details were taken

care of in preparing it. The problems encountered in various steps were taken into

account and eliminated to much extent so that they may not harm the project

functioning. Also certain areas were thought of before hand and worked upon, so

as to prevent them from becoming a limitation for the project. But, as it is that

every system is not perfect in all the aspects. They have some associated

limitations. Here are presented the advantages, in general and comparative of the

counterparts, and disadvantages of the project.

5.1ADVANTAGES:
1. Speed switches from sleeping to high mode of motor which save electricity
bill.

2. Economical design

3. Can be easily implemented in homes

4. Can be used by everyone at home to maintain a safe environment .

5.2DISADVANTAGES:
1. The system has no control over motor speed directly
2. It requires a android mobile phone which is connected to the system via
Bluetooth modem sometimes Bluetooth need to be reconnect.
 CHAPTER 6
APPLICATIONS
 6.1 APPLICATIONS

Permanent magnet BLDC motors will have a huge range of applications, and they are
the future of motor industry, as LED bulbs have replaced CFLs and tubelights.

Why I am saying this is because, they are very efficient in terms of energy
consumption (most efficient compared to all other motors), one of the reason they
have not been in the trend till now is because of the high cost of electronic power
circuitry involved with them, which is now decreasing exponentially, making them
comparable to induction motors.

Some of the qualities of BLDC motors are -

 High efficiency
 Very high Power to volume ratio ( a very small motor can give hundreds of
Watts of power output as in quadcopters)
 Zero maintenance as there are no brushes
 Easy control of speed
REFERNCES:

1. Paper of M.J Vanderwerff on ―activation of home automation

system via mobile technology‖

2. Wikipedia- Bluetooth technology

3. Data sheet of ATMEGA 168

4. www.motorola.com-interfacing device information

5. Dr. Aditya Trivedi-Prof. IIIT Gwalior

6. Labsguru workshop –programming details