MICROCONTROLLER BASED INDUSTRIAL SAFETY AND SECURITY SYSTEMS A PROJECT REPORT

Submitted by RAGHAVENDRAN R. (41501112025) SUBRAMANI C. (41501112029) MURUGAN K. (41501112016)

in partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING in INSTRUMENTATION AND CONTROL ENGINEERING

S.R.M. ENGINEERING COLLEGE, KATTANKULATHUR

ANNA UNIVERSITY :: CHENNAI 600025 MAY 2005

BONAFIDE CERTIFICATE

Certified that this project report MICROCONROLLER BASED INDUSTRIAL SAFETY AND SECURITY SYSTEMS is the bonafide work of SUBRAMANI C. (41501112029), RAGHAVENDRAN R. (41501112025) and MURUGAN K.

(41501112016) who carried out the project under my supervision.

SIGNATURE HEAD OF DEPARTMENT Department of Instrumentation and Control Engineering S.R.M. Engineering College Kattankulathur Kanchipuram-603203

SIGNATURE Dr. RANGANATH MUTHU SUPERVISOR PROFESSOR Department of Instrumentation and Control Engineering S.R.M. Engineering College, Kattankulathur Kanchipuram-603203

ABSTRACT In this project, five critical parameters namely fire, level, intruder, temperature and smoke are sensed and detected. The thermistor is used to detect the fire; the level sensors are used to detect the level at two levels. IR Transmitter and Receiver are used to detect the trespassing, temperature detector is used to detect temperature and smoke sensor is used to detect smoke. The sensors give the appropriate control signal to the microcontroller unit. The microcontroller unit gives the control signal to the controlling unit, like Water splashing unit, Motor control and Alarm unit. This project is mainly implemented in industries to sense the critical parameters and to control the same. By implementing this project the critical parameters are monitored continuously and the

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alarm signal is given for indication and the control action is also performed. This project is also a real time application and monitoring system. TABLE OF CONTENTS CHAPTER NO. TITLE ABSTRACT LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS AND NOMENCLATURE 1 INTRODUCTION 1.1 OUTLINE OF THE THESIS 1.2 BLOCK DIAGRAM OF THE PROJECT 1.3 REAL TIME APPLICATIONS OF THE PROJECT SENSOR DESCRIPTION 2.1 SMOKE SENSOR 2.2 TEMPERATURE SENSOR 2.3 WATER LEVEL DETECTION 2.4 FIRE DETECTION AND CONTROL LOOP 2.5 INTRUDER DETECTION SIGNAL CONDITIONING CIRCUIT 3.1 ANALOG TO DIGITAL CONVERTER 3.2 BLOCK DIAGRAM OF ADC CIRCUIT POWER SUPPLY 4.1 POWER SUPPLY COMPONENTS 4.2 CIRCUIT DIAGRAM OF POWER SUPPLY MICROCONTROLLER 5.1 ATMEL 89C51 5.2 PROGRAMMING RELAYS 6.1 INTRODUCTION 6.2 TYPES OF RELAYS 6.3 APPLICATION OF RELAYS PAGE NO. iii vi vii viii

1 3 4

5 8 11 13 17

20 21

22 24 25 28 36 37 39

MICROCONTROLLER BASED INDUSTRIAL SAFETY AND SECURITY SYSTEMS

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7.1 OVERVIEW OF THE PROJECT 7.2 BLOCK DIAGRAM OF THE ENTIRE PROJECT 8 RESULTS AND CONCLUSION 8.1 RESULT OF THE DESIGN 8.2 EXPECTATION AND IMPROVEMENT 8.3 CONCLUSION 9 APPENDIX 9.1 PROGRAM CODE FOR OPERATION 10 REFERENCES

40 42

43 45 45

46 56

LIST OF TABLES TABLE NO. 2.1 5.1 5.2 5.3 TITLE Smoke Detector Details Microcontroller Timer Operation 1 Microcontroller Timer Operation 2 Microcontroller Timer Operation 3 PAGE NO. 7 35 35 35

LIST OF FIGURES FIGURE NO. 1.1 2.1 2.2 2.3 2.4 2.5 TITLE Block diagram of the project Temperature Control Loop using LM 35 Block Diagram of Water Level Detection Loop Circuit Diagram of Water Level Detection Circuit diagram of Fire Detection Loop Block diagram of Fire Detection Loop PAGE NO. 3 10 12 13 16 16

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2.6 2.7 2.8 3.1 4.1 5.1 5.2 6.1 6.2 6.3 6.4 6.5 7.1

Block diagram of Intruder Detection Loop Circuit Diagram of IR Transmitter Circuit diagram of IR Receiver Block diagram of ADC circuit Circuit Diagram of Power Supply Circuitry Pin diagram of ATMEL 89C51 Control blocks of Microcontroller Diagram of a General Relay SPST Relay SPDT Relay DPST Relay DPDT Relay Circuit Diagram of the Entire Project LIST OF ABBREVIATIONS AND NOMENCLATURE Microcontroller

17 18 19 21 24 33 34 36 37 37 38 38 42

ABBREVIATIONS SS FD TS ID Smoke Sensor Fire Detector Temperature Detector Intruder detector Analog to Digital converter.

ADC -

NOMENCLATURE APOLLO SERIES 65 These are APOLLO made smoke sensors, which are highly sensitive and are used in industries This is a flash memory microcontroller -

ATMEL 89C51

CHAPTER 1 INTRODUCTION 1.1 OUTLINE OF THE THESIS Safety in industries is of paramount importance as it directly affects the productivity of the concerned industries. The use of dedicated software for safety and control applications began with the technological advancement in the field of MICROCONTROLLERS. With the advent of newer technologies, situations have turned around a lot and the need to view the live process in a system, within a control room has become essential. The various safety parameters that are monitored in this project are: Temperature control Water level indicator Fire Detection Intruder Detection Smoke detection

1.1.1 Temperature Control Loop The basic idea involved in this loop is to maintain the temperature of the room at a required ambient level. Temperature is one of crucial parameter, which has to be monitored and controlled in an industry. In this loop, continuous scanning of room temperature is done using a suitable sensor. By switching on/off the heating element, the room temperature can be maintained at the required level. 1.1.2 Intruder Detection It is of utmost importance in industries to detect intrusion in restricted area. The principle behind this loop is obstruction of infrared wave propagation by an intruder, which causes the activation of distress alarm. 1.1.3 Water Level Monitoring and Control

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The water level in a tank is monitored using a suitable sensor. So when the water reaches low level, a control signal is sent to activate the motor and as soon as water reaches the high level another control signal is sent to stop the motor. 1.1.4 Fire Detection Fire detection sensor is situated in a suitable position in the industry. As soon as there is accidental fire the sensor detects it and sends caution signal to the control room from were a control signa sent to actuate the fire extinguishing unit. 1.1.5 Smoke Detection An optical type smoke sensor is used for smoke detection. When the smoke

enters, it scatters photons on to the photodiode to excite it into activity. The LED then emits two further bursts of light, at 2-second intervals. If light is scattered on to the photodiode on both these pulses due to the presence of smoke, the detector will change to the alarm state. Then a silicon controlled rectifier on the printed circuit board is switched on and the current drawn by the detector is increased from an average of 40A to a maximum of 61mA. This comprises of a sensing chamber and a printed circuit board within a white polycarbonate housing. The sensing chamber is a black molding configured as a labyrinth which prevents ambient light penetrating into the chamber. The labyrinth has a fine gauge cover to prevent insects from migrating into the chamber. Within this chamber is an optical arrangement consisting of two main parts: an infrared light emitting diode and a photo diode. The LED is positioned at an obtuse angle to the photo diode, which has an internal daylight filter for further protection against ambient light. 1.2 BLOCK DIAGRAM OF PROJECT The block diagram of the project is shown in Fig 1.1.

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Fig. 1.1 Block diagram of the project 1.3 REAL TIME APPLICATIONS OF THE PROJECT 1.3.1 Industries In manufacturing and heavy engineering industries, refineries and many other process industries there is always a danger of fire and increase in temperature. In these areas, this project can be implemented effectively and in a most efficient manner. This also optimizes the working process and can be implemented in an effective way. 1.3.2 Domestic usage This project can also be implemented for domestic uses such as in homes and also in hotel and catering establishments, which are susceptible to hazards of smoke and fire. For personal usage this is a best way to prevent fire. 1.3.3 Highlights of this Project

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This is implemented in a comparatively cheap manner. This is operated using a microcontroller ATMEL 89C51 that has flash memory that can be reprogrammed.

CHAPTER 2 SENSOR DETAILS

2.1 SMOKE SENSOR The smoke sensor that is being used here is APPOLO series 60 optical detector type sensor. This comprises of a sensing chamber and a printed circuit board within white polycarbonate housing. The sensing chamber is a black molding configured as a labyrinth which prevents ambient light penetrating into the chamber. The labyrinth has a fine gauge cover to prevent insects from migrating into the chamber. Within this chamber is an optical arrangement consisting of two main parts: an infrared light emitting diode and a photo diode. The LED is positioned at an obtuse angle to the photo diode, which has an internal daylight filter for further protection against ambient light [Ross, 2004]. The LED emits collimated light for every 10 seconds. In clean air conditions, the photo diode will not receive light particles or photons due to the collimation of light and the angle at which the light is traveling relative to the photodiode. When the smoke enters the chamber, it scatters photons onto the photodiode to excite it into activity. The LED then emits two further bursts of light at 2-second intervals. If light is scattered onto the photodiode on both these pulses due to the presence of smoke, the detector will change to the alarm state. A silicon controlled rectifier on the printed circuit board is switched on and the current drawn by the detector is increased from an average of 40A to a maximum of 61mA. 2.1.1 Electrical Description Connection to the supply is made in the mounting between terminals L1 and L2 and the polarity is made insensitive. Terminal L1 IN is a supply input terminal and it is connected to Terminal L1 OUT via the detector when fitted. L1 OUT and L2 provide the supply output to the next detector on the zone or to the end of the line device. This

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method of connection permits continuous monitoring of the supply through the detector and the end of line device. A remote alarm indicator may be connected between the positive supply line and the R terminal. The R terminal is to protect it against accidental connection to the negative supply and to permit the connection of more than one detector to a single remote indicator. The current taken from the above terminal should be externally limited to 23mA. The Apollo remote indicator typically sinks 20mA. The supply range is 8V to 28V to the detector. The control unit must be arranged to supply a maximum of 28V and a minimum of 6V in the alarm condition for correct operation of the detector. To ensure effective illumination of the indicator, the supply to the indicator should exceed 12V. The electrical details of the smoke detector are tabulated in the Table 2.1 [EPA]. Table 2.1 Smoke Detector Details Average standby current (A) 38 37 25 1 Smoke alarm current (mA) 61 52 37 18

Supply voltage (V) 28 24 17 10

Pulse current (A) 110 90 60 1

Smoke alarm (mA) 54 48 33 16

It also has negative temperature coefficient thermistor. The alarm-reset time is 1 second. The alarm-reset voltage is 1V. In remote output characteristics there is 9000 resistor in series with a 3V drop at 24V with 5000 line impedance gives 1mA at 9V. The principle that is being used here is photoelectric detection of light scattered in a forward direction by smoke particles. The holding voltage is 6V and the holding current

is 10mA. In the chamber configuration there is a horizontal optical bench housing an infrared emitter and sensor arranged radically to detect forward scattered light. 2.2 TEMPERATURE SENSOR The temperature sensor that is used is LM 35 sensor. The LM 35 series are integrated circuit temperature sensors whose output voltage is linearly proportional to the Celsius temperature. The LM 35 thus has an advantage over linear temperature sensors calibrated in Kelvin, as the user is not required to subtract a large constant. This is also suitable for remote applications. This also has a very low impedance output [Blintliff, 1992]. 2.2.1 Applications This can be applied easily as any other integrated circuit temperature sensor. It can be glued or cemented to a surface. This is especially true for the TO-92 plastic package, where the copper leads are the principal thermal package and carry heat to the device so that its temperature might be closer to the air temperature rather than to the surface temperature. These devices are sometimes soldered to a small lightweight fin, to decrease the thermal time constant and speed up the response in a slowly moving air. The temperature control loop is a closed one in which the temperature of a processing zone has to be maintained at a temperature of 40C to 70C. A Blower is used to blow the air into the processing zone. From the processing zone the air is passed through closed pipe to heating zone, where it is heated by a heating coil and recycled into the processing zone by the blower unit.

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2.2.2 Temperature Control Loop The temperature control loop is a closed one in which the temperature of a processing zone has to be maintained at a temperature of 40C to 70C. A blower is used to blow the air into the processing zone. From the processing zone the air is passed through closed pipe to heating zone, where it is heated by a heating coil and recycled into the processing zone by the blower unit [Fischer, 1998]. 2.2.3 Sensing Unit

The LM 35 sensor is used to sense the temperature in the processing zone. The LM 35 gives the output from 0.1V to 1V for the temperature range of 0C to 100C. The output of LM 35 is amplified 5 times using LM 324 to give reference signal to the ADC 0809. The output of ADC 0809 is latched for 0.1 seconds using 74LS373 for every 6 seconds using 555 timer. The latched output is given to the ULN 2803 driver IC to drive the relay units. 2.2.4 Microcontroller Unit

Digital input of microcontroller is allocated to read the ADC output signal from relay units. The potential free contacts from relay units are connected to the digital inputs of the microcontroller. The microcontroller is programmed to convert the 8-bit digital data to the corresponding analog signal. The analog signal is compared with the set point and the appropriate control signal is given to the control unit from microcontroller [LM 324]. 2.2.5 Control Unit

If the temperature of the processing zone is above/below the set point, the heater is switched OFF/ON accordingly. Thus the appropriate control action takes place with the help of LM 35 sensor. 2.2.6 Block diagram of temperature control loop xii

The block diagram of the temperature control loop using LM 35 is depicted in the Fig.2.1.

Fig. 2.1 Temperature Control Loop using LM 35

2.3 WATER LEVEL DETECTION 2.3.1 Working System consists of two sensors-one to indicate low level and another to indicate high level. The signals from these sensors after proper conditioning are given as input to microcontroller, which, after going through given logics, control the pumping unit. A simple water level indicator & control circuit can be constructed using a comparator and relay. Whenever the water is at the low level, lead 1 senses it and gives an output pulse, which makes the motor ON and fills the tank. As the water level rises and reaches the high level, lead 2 senses it and switches the motor OFF .The output pulse is given to the motor through the relay section. This can also be implemented using a LDR circuit.

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Whenever the photoconductive cell has the appropriate light incident upon it, its resistance is low and the current through the relay is consequently high to operate the relay. When the light is interrupted or shut-off partially or completely, the resistance of the photocell increases thereby reducing the current through the relay. The current may drop down to a level where it will not be able to operate the relay there by de-energizing the relay [Northcutt, 2001]. The water level in a tank is monitored using a suitable sensor. So when the water reaches low level, a control signal is sent to activate the motor and as soon as water reaches the high level another control signal is sent to stop the motor.

2.3.2 Block diagram of Water level detection loop The block diagram of water level detection loop is shown in the Fig.2.2.

Fig. 2.2 Block Diagram of Water Level Detection Loop

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2.3.3 Circuit diagram of water level detection loop The circuit diagram of water level detection loop, which is implemented using a comparator and a relay, is shown in the Fig. 2.3.

Fig. 2.3 Circuit Diagram for Water Level Detection

2.4 FIRE DETECTION AND CONTROL LOOP

In this system, the fire is sensed by means of a suitable detector, which contains pair of matched negative temperature coefficient thermistors mounted on a printed circuit board within white polycarbonate housing. One thermistor is exposed and is therefore in good thermal contact with the surrounding air and responds quickly to changes in air temperature. The other thermistor is insulated from the surrounding air and responds more quickly to changes in temperature. Under stable conditions, both the thermistors are in thermal equilibrium with the surrounding air and will have the same resistance value If the air temperature increases rapidly then a temperature difference develops between the thermistors and the resistance

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of the exposed thermistors becomes less than that of the insulated thermistor. The ratio of the resistances of the thermistors is monitored electronically and a fire alarm is initiated if the ratio exceeds the limit. The detector is designed to be connected to a two wire monitored supply of between 17V and 28V. 2.4.1 Thermistor Thermistor is a contraction of the term thermal resistors. These are composed of semi-conductor materials. This allows the thermistor circuits to detect very small changes in temperature, which could not be observed with an RTD or a thermocouple. Thermistors are widely used in applications, which involve measurements in the range of -60C to 15C. The resistance of thermistors ranges from 0.5 to 0.75 M . They exhibit highly non-linear characteristics of resistance versus temperature [Sonnewald, 1998].

2.4.1.1 Construction

They are composed of sintered mixture of metallic oxides such as manganese, nickel, cobalt, copper, iron and uranium. They are available in variety of sizes and shapes. They may be in the form of leads, rods and discs. 2.4.1.2 Resistance-temperature characteristics: RT1=RT2 exp [ (1/T1 1/T2)] where RT1 = Resistance of thermistor at absolute temp T1 (K) RT2 = Resistance of the thermistor at absolute temp T2 (K) = A constant depending upon the material of thermistor The above characteristics show that the thermistor has a very high negative temperature co-efficient of resistance, making it an ideal temperature transducer. (2.1)

2.4.1.2 Working

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A thermistor produces a large change of resistance with a small change in the temperature being measured. This large sensitivity of thermistor provides good accuracy and resolution. A typical industrial-type thermistor with a 2000 resistance at 25C and a resistance temperature coefficient of 3.9% per C exhibits a change of 78 per degree celsius change in temperature. A simple temperature control circuit is constructed using comparator and relay. Any change in temperature causes a change in resistance of thermistor and an unbalance voltage is fed to an op-amp whose output excites relay coil. The relay contacts are used to control the current in the circuit, which generates the heat. 2.4.1.3 Features of Thermistors Thermistors are compact, rugged and inexpensive Thermistors when properly aged, have good stability 2.4.1.4 Circuit diagram of fire detection loop The circuit diagram of fire detection loop is given in Fig. 2.4.

Fig 2.4 Circuit diagram of Fire Detection loop 2.4.1.5 Block diagram of fire detection loop The block diagram of fire detection loop is shown in the Fig. 2.5.

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Fig. 2.5 Block diagram of Fire Detection Loop 2.5 INTRUDER DETECTION 2.5.1 IR Transmitter Infrared transmission is placed on one side and the transmitter is placed on other side. When there is an intrusion, the path of propagation is disturbed and a signal is sent to the microcontroller, which in turn raises an alarm based upon the logic given to it. 2.5.2 Block diagram of intruder detection loop The block diagram of intruder detection loop is shown in the Fig. 2.6.

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Fig. 2.6 Block diagram of Intruder Detection Loop 2.5.3 Circuit diagram of IR transmitter The circuit diagram of IR transmitter is shown in the Fig. 2.7.

Fig. 2.7 Circuit Diagram of IR Transmitter

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2.5.4 Circuit diagram of IR receiver The circuit diagram of IR receiver is shown in the Fig.2.8.

Fig. 2.8 Circuit diagram of IR Receiver

CHAPTER 3 SIGNAL CONDITIONING CIRCUIT

3.1 ANALOG TO DIGITAL CONVERTER (ADC) Tracking A/D converter is a device commonly used in control system. Here an up down-counter controls the DAC and the clock pulses are directed to pertinent counter

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input depending on whether the D/A output must increase or decrease to reach the analog input voltage. The obvious advantage of the A/D converter is that it can continuously follow the input signal and give updated digital output data if the signal does not change too rapidly. Also, for small input changes, the conversion can be quite fast. The converter can be operated in either the track or hold modes by a digital input control. The block diagram of a successive approximation register (SAR) is shown. It consists of a DAC, as comparator, and a successive approximation register. One terminal is required for analog input voltage. The digital output is available in either serial or parallel form. A minimum of three-control terminal is required. Start of conversion (SOC) initiates an A/D conversion and End of conversion (EOC) tells when the conversion is completed. An external clock terminal sets the time to complete each conversion. 3.2 BLOCK DIAGRAM OF ADC CIRCUIT The block diagram of the ADC circuit is shown in the Fig. 3.1.

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Fig. 3.1 Block diagram of ADC Circuit CHAPTER 4 POWER SUPPLY

Most electronic circuits need a source of D.C. power. For our device a simple power supply is sufficient where the input voltage is converted to D.C. through full wave rectification. 4.1 POWER SUPPLY COMPONENTS The power supply unit consists of Transformer xxii

Bridge rectifier Voltage regulators Filter circuit

4.1.1 Transformer When A.C. is applied to the primary winding of the power transformer it can either be stepped down or up depending on the value of the D.C. needed. In our circuit the transformer performs the step-down operation where the 230V A.C. appears as 12V A.C. across the secondary winding (practically as 15V A.C.). One alteration of the input voltage will cause the top of the transformer to be positive and the bottom negative. The next alteration will cause the polarity reverse. The current rating of the transformer used in this project is 1A. 4.1.2 Bridge Rectifier A commonly used circuit for supplying large amounts of DC power is the bridge rectifier. In this rectifier configuration, we have used four diodes. Two diodes will conduct during the negative alternation and two will conduct during positive alternation. The bridge transformer is used in the half wave rectifier. The DC output voltage appearing across the output of the bridge circuit will be somewhat less than 90% of the applied R.M.S. value. A boosting capacitor is provided for boosting the DC voltage. 4.1.3 Voltage Regulator Due to the fluctuation in the supply we need a regulator to provide a constant voltage of 5V. The IC regulator 7805 produces a constant voltage of 5V and IC Regulator 7812 produces a constant voltage of 12V for a given input ranging from 17.5V to 7.5V. The DC output produced will be a unidirectional pulsating current with a ripple frequency of 120Hz. 4.1.4 Filter Circuit

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ICs are always followed by filter circuit which is usually a capacitor acting as a surge arrester. This capacitor, also called as a DC coupling capacitor or bypassing capacitor, is used to short the ripple with frequency of 120 Hz to ground but leave the DC frequency to appear at the output. The load resistor R is connected so that a reference to the ground is maintained. The load resistor should be 1% to 2.5% of the load.

4.2 CIRCUIT DIAGRAM OF POWER SUPPLY The circuit diagram of power supply circuitry is shown in the Fig. 4.1.

Fig. 4.1 Circuit Diagram of Power Supply Circuitry

CHAPTER 5 MICROCONTROLLER

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5.1 ATMEL 89C51 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 nonvolatile 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 nonvolatile 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. The AT89C51 provides the following standard features: 4K bytes of flash, 128 bytes of RAM, 32 I/O lines, 16-bit timers/counters, a five vector two-level interrupt architecture, full duplex serial port, on-chip oscillator and clock circuitry. In addition, the AT89C51 is designed with static logic for operation down to zero frequency and supports two software selectable power saving modes. The Idle Mode stops the CPU while allowing the RAM, timer/counters, serial port and interrupt system to continue functioning. The Power-down Mode saves the RAM contents but freezes the oscillator disabling all other chip functions until the next hardware reset.

5.1.1 Pin Description 5.1.1.1 VCC Supply voltage to the microcontroller is 5V. 5.1.1.2 GND Supply voltage to the microcontroller is 0V. 5.1.1.3 Port 0 Port 0 is an 8-bit open-drain bi-directional I/O port. As an output port, each pin can sink eight TTL inputs. When 1s are written to Port 0 pins, the pins can be used as

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high impedance inputs. Port 0 may also be configured to be the multiplexed low order address/data bus during accesses to external program and data memory. In this mode Port 0 has internal pull-ups. Port 0 also receives the code bytes during flash programming, and outputs the code bytes during program verification. External pull-ups are required during program verification. 5.1.1.4 Port 1 Port 1 is an 8-bit bi-directional I/O port with internal pull-ups. The Port 1 output buffers can sink/source four TTL inputs. When 1s are written to Port 1 pins they are pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 1 pins that are externally being pulled low will source current (IIL) because of the internal pull-ups. Port 1 also receives the low-order address bytes during Flash programming and verification. 5.1.1.5 Port 2 Port 2 is an 8-bit bi-directional I/O port with internal pull-ups. The Port 2 output buffers can sink/source four TTL inputs. When 1s are written to Port 2 pins they are pulled high by the internal pull-ups and can be used as inputs. As inputs, port 2 pins that are externally being pulled low will source current (IIL) because of the internal pull-ups. Port 2 emits the high-order address byte during fetches from external program memory and during accesses to external data memory that uses 16-bit addresses (MOVX @DPTR). In this application, it uses strong internal pull-ups when emitting 1s. During accesses to external data memory that uses 8-bit addresses (MOVX @ RI), Port 2 emits the contents of the Port 2 Special Function Register. Port 2 also receives the high-order address bits and some control signals during Flash programming and verification. 5.1.1.6 Port 3 Port 3 is an 8-bit bi-directional I/O port with internal pull-ups. Port 3 output buffers can sink/source four TTL inputs. When 1s are written to Port 3 pins they are pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 3 pins that

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are externally being pulled low will source current (IIL) because of the pull-ups. Port 3 also receives some control signals for Flash programming and verification.

5.1.1.7 RST This is Reset input (RST). A high on this pin for two machine cycles while the oscillator is running resets the device. 5.1.1.8 ALE/PROG Address Latch Enable (ALE) output pulse for latching the low byte of the address during accesses to external memory. This pin is also the program pulse input (PROG) during flash programming. In normal operation ALE is emitted at a constant rate of 1/6 the oscillator frequency, and may be used for external timing or clocking purposes. 5.2 PROGRAMMING The AT89C51 is normally with the on-chip flash memory array in the erased state (that is, contents = FFH) and ready to be programmed. The programming interface accepts either a high-voltage (12V) or a low-voltage (VCC) program enable signal. The low-voltage programming mode provides a convenient way to program the ATMEL 89C51 inside the users system, while the high-voltage programming mode is compatible with conventional third party Flash or EPROM programmers. The AT89C51 is made with either the high-voltage or low-voltage programming mode enabled. The AT89C51 code memory array is programmed byte by byte in either programming mode. To program any nonblank byte in the on-chip Flash Memory, the entire memory must be erased using the Chip Erase Mode. 5.2.1 Programming Algorithm 5.2.1.1 Data Polling

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The AT89C51 features data polling to indicate the end of a write cycle. During a write cycle, an attempted read of the last byte written will result in the complement of the written datum on Port 0.7. Once the write cycle has been completed, true data are valid on all outputs, and the next cycle may begin. Data polling may begin any time after a write cycle has been initiated. 5.2.1.2 Ready/Busy The progress of byte programming can also be monitored by the RDY/BSY output signal. Port 3.4 pulled low after ALE goes high during programming to indicate BUSY. Port 3.4 is pulled high again wh programming is done to indicate READY. 5.2.1.3 Program Verify If lock bits LB1 and LB2 have not been programmed, the programmed code data can be read back via the address and data lines for verification. The lock bits cannot be verified directly. Verification of the lock bits is achieved by observing that their features are enabled. 5.2.1.4 Chip Erase The entire flash array is erased electrically by using the proper combination of control signals and by holding ALE/PROG low for 10 ms. The code array is written with all 1s. The chip erase operation must be executed before the code memory can be reprogrammed. 5.2.1.5 Reading the Signature Bytes The signature bytes are read by the same procedure as a normal verification of locations 030H, 031H, and 032H, except that P3.6 and P3.7 must be pulled to logic low. The values returned are as follows. (030H) = 1EH indicates manufactured by Atmel (031H) = 51H indicates 89C51 xxviii

(032H) = FFH indicates 12V programming (032H) = 05H indicates 5V programming 5.2.2 Programming Interface Every code byte in the Flash array can be written and using the appropriate combination of cont signals can erase the entire array. The write operation cycle is self timed and once initiated, w automatically time itself to completion. All major programming vendors offer worldwide support for ATMEL microcontroller series. 5.2.3 AT89C51 In-Circuit Programming This illustrates the in-circuit programmability of the ATMEL AT89C51 Flashbased microcontroller. A method is then shown which can reprogram the AT89C51 microcontroller in the application remotely, over a commercial telephone line. The circuitry described here supports 5V programming only, requiring the use of an AT89C51. The standard AT89C51 requires 12V for programming. 5.2.4 General Considerations Circuitry added to support AT89C51 in circuit programming should appear transparent to the application when programming is not taking place. EA/VPP must be held high during programming. In applications that do not utilize external program memory, this pin may be permanently strapped to VCC. Applications utilizing external program memory require that this pin be held low during normal operation. RST must be held active during programming. A means must be provided for overriding the application reset circuit, which typically asserts RST only briefly after power is applied. PSEN must be held low during programming, but must not be driven during normal operation. ALE/PROG is pulsed low during programming. But must not be driven during normal operation. During programming, AT89C51 I/O ports are used for the application of mode select, addresses and data, possibly requiring that the controller be isolated from the application circuitry.

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5.2.4.1 Port Used for Input During programming, the controller must be isolated from signals sourced by the application circuitry. A buffer with three state outputs might be inserted between the application circuitry and the controller, with the buffer outputs three stated when programming is enabled. Alternately, a multiplex might be used to select between signal sources, with signals applied to the controller by either the application circuitry or the programmer circuitry. 5.2.4.2 Port Used for Output No circuit changes are required if the application circuitry can tolerate the state changes which occur at the port during programming. If the prior state of the application circuitry must be maintained during programming, a latch might be inserted between the controller and the application circuitry. The latch is enabled during programming, preserving the state of the application circuitry. Programming requires programmer access to all of the four AT89C51 I/O ports. The programmer generates the addresses, data and control signals necessary to program the AT89C51 embedded in the application. The programmer circuitry consists of an AT89C51 and an RS-232 level translator. The controller runs at 11.0592 MHz, which allows the serial port to operate at a number of standard baud rates. A Maxim MAX232 line driver/receiver produces RS-232 levels at the serial interface while requiring only a 5V supply. Many of the signals generated by the programmer are connected directly, without buffering, to the AT89C51 in the application. These signals, when inactive, are pulled high. The AT89C51 has internal pull-ups of approximately 3 on ports one, two and three. Because port zero does not have internal pull-ups, external pull-ups of 10 have been added to permit proper operation of program verification mode. The sample application operates correctly in this environment. If required for compatibility with an application, programmer signals may be buffered with three-state buffers. The AT89C51 in the programmer does not utilize external program or data memory, which would require sacrificing needed I/O pins. This requires that program code and I/O buffers be kept small enough to fit in on-chip memory. 5.2.5 Pin diagram of the microcontroller

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The pin diagram of the microcontroller ATMEL 89C51 is shown in the Fig. 5.1.

Fig. 5.1 ATMEL 89C51 Microcontroller 5.2.6 Control blocks of the microcontroller The block diagram of the microcontroller is shown in the Fig. 5.2.

Pin diagram of

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5.2 Control blocks of Microcontroller

5.2.7 Timer operations The timer operations of the microcontroller are tabulated in tables 5.1, 5.2 and 5.3 respectively.

Table 5.1 Microcontroller Timer Operation 1 SFR TH0 TLO TH1 TL1 TCON NAME Timer 0 Timer 0 Timer 1 Timer1 Timer control DESCRIPTION High Byte Low byte High byte Low byte SFR ADDRESS 8CH 8AH 8DH 8BH 88H

Table 5.2 Microcontroller Timer Operation 2 TxM1 0 0 1 TxM0 1 0 1 Timer Mode 1 2 3 Description of Mode 13 BIT TIMER 16 BIT TIMER AUTO RELOAD

Table 5.3 Microcontroller Timer Operation 3 INSTRUCTION MOV TL0, #01 MOV TMOD, #01 SETB TR0 JNB TF0, $ OPERATION PERFORMED Low byte of 19,457 (19,456 + 1 = 19,457) Put Timer 0 in 16-bit mode Make Timer 0 start counting If TF0 is not set, jump back to this instruction.

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CHAPTER 6 RELAYS

6.1 INTRODUCTION A relay is used to isolate one electrical circuit from another. It allows a low current control circuit to make or break an electrically isolated high current circuit path. The average remote lead can only handle about one half of an amp of current. If a circuit with a large amount of current must be controlled by the remote output lead of a head unit, a relay could be used to buffer the remote output from the head unit. The basic relay consists of a coil and a set of contacts. The most common relay coil is a length of magnet wire wrapped around a metal core. 6.1.1 Diagram of a General Relay The diagram of a general relay is shown in the Fig. 6.1.

6.1 Diagram of a General Relay

6.2 TYPES OF RELAYS 6.2.1 SPST Relay

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This is a Single Pole Single Throw relay. Current will only flow through the contacts when the relay coil is energized. The diagram of SPST relay is shown in the Fig 6.2.

6.2 SPST Relay 6.2.2 SPDT Relay This is a Single Pole Double Throw relay. Current will flow between the movable contact and one fixed contact when the coil is de-energized and between the movable contact and the alternate fixed contact when the relay coil is energized. The diagram of SPDT relay is shown in the Fig.6.3.

Fig. 6.3 SPDT Relay 6.2.3 DPST Relay

This is a Double Pole Single Throw relay. When the relay coil is energized, two separate and electrically isolated sets of contacts are pulled down to make contact with their stationary counterparts. There is no complete circuit path when the relay is deenergized. The diagram of DPST relay is shown in the Fig. 6.4.

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Fig. 6.4 DPST Relay 6.2.4 DPDT Relay

This relay is a Double Pole Double Throw relay. It operates like the SPDT relay but has twice as many contacts. There are two completely isolated sets of contacts. The diagram of DPDT relay is shown in the Fig 6.5.

Fig. 6.5 DPDT Relay

6.3 APPLICATIONS OF RELAYS A relay is used to isolate one electrical circuit from another. It allows a low current control circuit to make or break an electrically isolated high current circuit path. The average remote lead can only handle about one half of an amp of current. If a circuit with a large amount of current must be controlled by the remote output lead of a head unit, a relay could be used to buffer the remote output from the head unit.

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CHAPTER 7 MICROCONTROLLER BASED INDUSTRIAL SAFETY AND SECURITY SYSTEMS

7.1 OVERVIEW OF THE PROJECT

In this project we are monitoring and detecting five critical parameters namely 1) Temperature 2) Smoke 3) Fire 4) Intruder and 5) Level Temperature sensor used in this project is LM 35 sensor. According to the rise and fall in temperatures, the heating element is made on or off. Smoke sensor is APOLLO made series 60 optical detector. When smoke enters the chamber, it scatters photons on to the photodiode to excite it into activity. The LED then emits light at 2second intervals. If light is scattered on to the photodiode due to the presence of smoke, the detector will change into the alarm state and the microcontroller will take the corresponding control action. Fire is detected by means of fire detectors, which mainly incorporate two thermistors. If the air temperature increases rapidly an alarm is initiated so that the microcontroller will take the corresponding control action. In intruder detection, IR receiver is placed on one side and the transmitter is placed on other side. When there is an intrusion, the path of propagation is disturbed and a signal is sent to the microcontroller, which in turn raises an alarm based upon the logic given to it. For water level detection the water level in a tank is monitored using a suitable sensor. So when the water reaches low level, a control signal is sent to activate the motor and as soon as water reaches the high level another control signal is being sent to stop the motor. Microcontroller used in this project is ATMEL 89C51, which is a flash memory reprogrammable microcontroller. A/D converter is also used as a signal conditioning element. This project is mainly implemented in industries to sense the critical parameters and to control the same. By implementing this project the critical parameters are monitored continuously and the alarm signal is given for indication and the control action is also performed. This project is also a real time application and monitoring system.

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7.2 BLOCK DIAGRAM OF THE ENTIRE PROJECT

The circuit diagram of the entire project is shown in Fig. 7.1.

Fig. 7.1 Block Diagram of the Entire Project

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CHAPTER 8 RESULTS AND CONCLUSION 8.1 RESULT OF THE DESIGN 8.1.1 Speed of Execution

The speed of the execution is 564 ms. If a particular sensor is enabled, the LCD screen will output a * symbol before the sensor name. User can also set the alert temperature, enable/disable voice or buzzer alarm, and even specify the ring tone and frequency of the buzzer alarm and the time before voice alarm goes off. The button debounce scheme also works fine so users can navigate through the menu and use the keypad perfectly.
8.1.2 Accuracy

After the user enables the security system, the green status LED will be lit to indicate the system status. User can now enter proper password to unlock the system. If any sensor goes wrong, the LCD will output ERROR and with proper initial for the sensor (T for temperature, M for motion, S for smoke, D for door or window magnetic switch). The red led light will flash at 4 Hz to indicate such an event. If the buzz alarm is enabled, it will sound the tone that user choose. If the voice alarm is enabled, it will wait for few seconds (user specified), if the system is still not locked, then it will start playing voice to indicate which sensor had gone wrong. (For example, Temperature Error, please check and unlock the security system.). If another sensor goes wrong after that, the system will also act accordingly and indicate that in the voice alert in addition to the LCD screen. (Temperature Motion Error, please check and unlock the security system.).
8.1.3 Safety

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There are two kinds of smoke detectors, ionization chamber and photoelectric smoke detectors. Our detector is optical type. So there is no concern for any radiation coming from our detector.
8.1.4 Usability

Our home security system is very practical. It can be used not only in the home environment but also in a business environment too. It can monitor the surrounding to not only protect our properties but also our lives. Besides, it can be highly customized to suit one's need and preference. So our security system is very useful for us as well as other people. We believe every house in the world should equip a security system like the one we have designed.

8.2 EXPECTATION AND IMPROVEMENT

The result of our design has met our expectation, in which every sensor is working and will sound specific alarm when the system goes into alert status. The keypad and LCD also offer great interface and users can be familiar with our system in less than few seconds. If we have chance to design this project again, we will add a phone dialer chip like the Zarlink MT8880C we had mentioned before. By doing so, we can make sure that if no one is at home or if no one is around the area, someone else can be notified to take immediate action. In addition, we feel like our PORT B is a little bit wasted. Besides, we will like to have another small microcontroller at a higher frequency, so we can output our buzz alarm at a higher frequency tone.
8.3 CONCLUSION

This project is done mainly considering safety and security of the equipments and the industry. The heart of this project is a microcontroller, which does all the activities like monitoring, displaying and controlling the given parameters. In this project we have monitored and controlled the five critical parameters like intruder, water level, temperature, smoke and fire. This project can also monitor and control more than five parameters by adding more number of interfacing circuits and control units. This project can be used for domestic purpose as well as industrial usage. The main advantage of this project is simple and easy method of controlling and it requires very low voltage for its

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operation and also faster in controlling the input parameters. So with this project can safe guard the equipments and prevent heavy loses. Also, it guards the work place and improves the safety and security of the industry.
CHAPTER 9 APPENDIX

9.1 PROGRAM CODE FOR OPERATION

#include "reg52.h" #include "stdio.h" #include "string.h" data unsigned char temp; data unsigned char val; char line1[16]; char line2[16]; sbit RS = P3^2; sbit RW = P3^3; sbit EN = P3^4; sbit BF = P1^7; sbit ADCSC = P3^5; // inputs sbit intr = P0^5;

sbit low = P0^6; sbit high = P0^7; sbit smoke sbit heat = P3^7; = P3^6;

sbit inc = P3^0; sbit dec = P3^1;

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// outputs sbit heating = P0^0; sbit blower = P0^1; sbit pump = P0^2; sbit flash = P0^3; sbit alarm void dely(void) { int j; for(j=0;j<5000;j++); } void delay(void) { int j; for(j=0;j<10000;j++); } void lcdready(void) { EN=0; P1=0xff; RS=0; RW=1; while(BF==1) { EN=0; EN=1; } EN=0; } void command(unsigned char lcddata) = P0^4;

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{ lcdready(); P1=lcddata; RS=0; RW=0; EN=1; EN=0; } void display(unsigned char lcddata) { lcdready(); P1=lcddata; RS=1; RW=0; EN=1; EN=0; } lcddisplay(char *buff1,char *buff2,int x) { data char value; int len1,i,len2; len1=strlen(buff1); len2=strlen(buff2); value=0x3c; command(value); value=0x0e; command(value); value=0x06; command(value); value=0x01; xlii

command(value); value=0x80; command(value); for(i=0;i<len1;i++) { value=buff1[i]; display(value); if(x==1) delay(); } value=0xc0; command(value); for(i=0;i<len2;i++) { value=buff2[i]; display(value); if(x==1) delay(); } } void main() { int sp=40; int ap=32; pump = 0; blower = 0; heating = 0; alarm = 0; flash = 0; lcddisplay(" S.R.M ENGG "," COLLEGE ",1); xliii

delay(); lcddisplay(" INDUSTRIAL"," SAFETY SYSTEM",1); delay(); lcddisplay("This Project ","is Done by ",1); delay(); lcddisplay(" C.SUBRAMANI ","R.RAGHAVENDRAN ",1); delay(); lcddisplay(" AND "," K.MURUGAN ",1); for(;;) { P2 = 0xff; ADCSC=0; dely(); ADCSC=1; temp=P2; ap=(int)temp; sprintf(line1,"Zone Temp:%d'C",ap = (int)(ap/5)*3); sprintf(line2,"Set Point:%d'C ", sp ); delay(); lcddisplay(line1,line2,0); delay(); if(sp < ap) { heating = 0; } if((sp-5)> ap) { blower = 1; } if((sp - 10) > ap) { heating = 1; } inc = 1; xliv

if(inc == 0) { sp++; if(sp >= 60) sp = 30; inc = 1; while (inc==0); } dec = 1; if(dec == 0) { sp--; if(sp < 30) sp = 60; dec = 1; while (dec==0); }

low = 1; high = 1; if(low == 1 && high == 1) { pump = 1; lcddisplay("Level","Low",1); } if(high == 0 && low ==0 ) { pump = 0; }

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intr = 1; dely(); if(intr ==1) { alarm = 1; lcddisplay("INTRUDER","ALARM ENABLE",1); while(inc==1) { inc =1; } alarm = 0; lcddisplay("INTRUDER","ALARM DISABLE",1); } heat = 1; dely(); if(heat == 0) { flash = 1; lcddisplay("FIRE ALARM ","ENABLE",1); inc = 1; while(inc == 1) { inc=1; flash = 0; lcddisplay("FIRE ALARM ","DISABLE",1); } smoke = 1; dely(); if(smoke == 0) { flash = 1; }

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lcddisplay("SMOKE ALARM ","ENABLE",1); inc = 1; while(inc == 1) { inc=1; }

flash = 0; lcddisplay("SMOKE ALARM ","DISABLE",1); } } } This program was initially done in C and loaded into the microcontroller using Keil compiler.

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CHAPTER 10 REFERENCES

10.1 WEB REFERENCES

1. EPA - Smoke Detector and Radiation http://www.epa.gov/radiation/sources/smoke_alarm.htm 2. LM34 specification http://instruct1.cit.cornell.edu/courses/ee476/labs/s2004/LM34. pdf

10.2 TEXT BOOK REFERENCES

1. Blintliff R.L, (1992) The Corporate Manual of Corporate and Industrial Security, Prentice Hall, London. 2. Fischer R.J and Green.G, (1998) Introduction to Security, Sixth edition, Buttenworth-Heinemann, Boston. 3. Northcutt and Novak, (2001) Network Intrusion and Detection An Analysts Handbook, 2nd Edition, New Riders. 4. Ross Anderson, (2004) Security Engineering-A Guide to Building Dependable Distributed Systems, Wiley and Sons, USA. 5. Sennewald C.A, (1998) Effective Security Management, 3rd Buttenworth-Heinemann, Boston. Edition,

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